Process Planning & Audit QRA Sourcing Risk: Monitoring Level Review: PA - Readiness Eval.

EMEA / LATAM QRA Program Risk: Date: Review #:

Supplier Supplier
Part Number: OdM:
Code: Name:
Part Supplier
MY: Vehicle: SQE:
Description: Plant:
PROCESS VERIFICATION (VP) PRE-SERIES (PS) RELEASE TO PROD.(DaP) CURRENT PRODUCTION
Material Req. Date: Material Req. Date: Material Req. Date: Material Req. Date:
PROCESS AUDIT Full Approval
Planning
Build Date / Avail.: Build Date / Avail.: Build Date / Avail.: Build Date / Avail.: READINESS EVALUATION

2 - PROCESS
1 - PART DESIGN 3 - PROCESS CONTROL 4 - PROCESS CONTROL 5 - OPERATIONS 6 - LOGISTICS 7 - VERIFICATION 8 - QUALITY SYSTEMS 9 - FULL APPROVAL
DEVELOPMENT

Source Package & Technical

Program
Review
Management & TimingControl Plan Process Monitoring Work Instructions Material Handling Capacity, Volume & PDR Non-Conformance Management
Planning
& Corrective
of Self-Qualification
Actions Tests

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Design FMEA Process Flow Diagram Incoming & Outgoing Inspection

Layered Process Audit Maintenance Traceability & Part Identification
Process Performance & Capability
Sub-Tier Management Planning of Integrative Tests

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Design Model & Release Process FMEA Error & Mistake Proofing Safety & Report Characteristics
Rework & Repair Packaging SQE Audit Lessons Learned Planning of Matchability / Benestare

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Special Characteristics Tooling Development & Pilot

Gages
Parts& Measuring DevicesFirst Piece Approval Training Sequenced Part Delivery Sub-Component Approval Warranty IMDS

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Change Management Sub-Component Development

Safe Launch Activities Special Processes Environment Health & Safety CAPMAN Annual Validation & Periodic
Quality Certifications & Record#Retention
Recertification of NV Results
(no approval if >0)
E

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NA - Not Applicable 2 - JOB STOPPER 5 - Implemented SCORING OPEN ISSUE & = Documents
1 - JOB STOPPER Risk 3 - Moderate Risk 4 - Low Risk Activity DEFINITIONS
SCORING
CONTACT LIST OBSERVATION
OPEN ISSUE &
Acceptable
NV - Not Evaluated CONTACT LIST DA
DEFINITIONS OBSERVATION

Supplier Program SQE / SQ CMS /

Resp.: Mgr: SQ TL: SQ CMT:
Name Sign. Name Sign. Name Sign. Name Sign.

Process Audit v1.0 April 2012

Item # Name Requirements for Closure Documents Required Target to Start Target for PPR Kick-Off Meeting Activities Ongoing PPR Activities Process Audit Activities Score Reference
Completion
* Applicable Source Package
* Source Package Boilerplate (NAFTA)
The Supplier shall have available and have reviewed the Source Package, Review the completed Source Package, AQR, MFA, and * FGP 01 (EMEA / LATAM)
Additional Quality Requirements (AQR), Supplier-completed Manufacturing * Source Package for EMEA/LATAM the SoR, noting key information and
* AQR Ensure Supplier is incorporating AQR requirements into Verify all requirements listed in the AQR
Feasibility Assessment (MFA) for the part (signed by all applicable FCA and * Signed MFA program deliverables. Verify all issues raised by the process, as applicable. Review open issues from have been incorporated into the process,
Supplier representatives), and for EMEA/LATAM the signed Statement of * Signed Statement of After source selection Prior to TKO potential Suppliers during the sourcing phase have the MFA and (for EMEA / LATAM) SoR to ensure including the PFMEA, Control Plan, and
Requirements (SoR). All requirements listed in the AQR shall be incorporated been discussed and adequately addressed. Ensure
Source Package & into the manufacturing process and included in the design model, test plan, Requirements (SoR) - engineering specifications and Quality, Reliability, and closure. Error and Mistake-Proofing.
1A Technical Review Control Plan, or other technical documentation, as applicable. EMEA/LATAM Supply requirements are understood by the Supplier.

* Quality First process

A Quality Risk Assessment shall be completed for each part, with Sourcing Technical Review (or Prior to Source Review the results of the Quality Risk Assessment Verify the progress of any planned corrective actions Verify planned corrective actions from QRA * FGP 01 (EMEA / LATAM)
percentage provided to Purchasing for the Quality First process and Program * Quality Risk Assessment Process Technical (QRA) with the team. Verify the progress of any
Risk entered into the applicable FCA systems by required FCA timing. Review) Selection planned corrective actions from QRA open issues. from QRA open issues. open issues are complete.

* Potential Failure Mode & Efects Analysis

Verify the responsibility for the part design and Design manual (4th Edition)
A Design Failure Mode & Efects Analysis (DFMEA) shall be available for all FMEA between FCA Engineering and the Supplier. * FIAT Norm 00270 / 00271
parts. It shall be created using all FCA guidelines and the AIAG Potential Failure Review initial DFMEA with FCA Engineering and Verify the DFMEA has been updated to the latest Verify the DFMEA has been updated to the * ISO/TS-16949 7.3.3.2
latest design release. Note: if FCA is design
Mode & Efects Analysis (4th Edition) manual. NOTE: Approval of the Process * Design FMEA Initial design concept Prior to TKO Supplier. Ensure Supplier has access to any applicable design release. Note: if FCA is design responsible and responsible and no DFMEA exists, mark the
Audit shall not be withheld if a DFMEA does not exist for a FCA-designed part; FCA guidelines for creation of DFMEAs. Note: if FCA is no DFMEA exists, mark this "N/A" item "N/A"
in such a situation, mark this item "NA". design responsible and no DFMEA exists, mark this
"N/A"

* Potential Failure Mode & Efects Analysis

manual (4th Edition)
* FIAT Norm 00270 / 00271
* ISO/TS-16949 7.3.3.2
The DFMEA shall be reviewed and accepted by the FCA Engineering
Ensure the FCA Engineer has reviewed the DFMEA (if
representative. The Supplier shall ensure the DFMEA meets all requirements, Supplier-responsible) and agrees to the contents.
including but not limited to: Ensure it was developed taking into account lessons Ensure open issues have been closed.
- inclusion of all special characteristics;
- inclusion of all applicable sub-components; learned from previous programs and action plans exist Ensure the FCA Engineer has accepted the
- inclusion of all error-proofing; * Design FMEA Initial design concept Prior to TKO for items with the highest risk. Verify inclusion of all Track and follow open issues. latest version of the document. Verify all
special characteristics, BSR/NVH items, and sub- planned error and mistake-proofing, and
1B Design FMEA - inclusion of all reliability targets and requirements; components. Verify items with a Severity greater than ensure all controls listed in the DFMEA
- review of all potential BSR/NVH situations; or equal to 8 have adequate error-proofing planned or have been applied.
- special attention given to items with high severity (8+), an inability to be
detected (10), or high end-customer dissatisfaction (severity 5+ and actions are taken to minimize the severity via design.
occurrence 4+). Document any open issues or concerns.

* Potential Failure Mode & Efects Analysis

manual (4th Edition)
The Supplier shall have a procedure for development of DFMEAs and records * FIAT Norm 00270 / 00271
that ensure all DFMEAs are periodically reviewed and evaluated for continuous * ISO/TS-16949 7.3.3.2
improvement of failure modes. Failure modes identified as the highest risk
shall be addressed first. The procedure shall also include: * Procedure for development of
- determination of severity, occurrence, and detection values; FMEAs Systemic Review procedure for concurrence to requirements.
- regular reviews and updates for lessons learned (e.g., yardholds, field
campaigns) and internal / external benchmarking;
- updates of the DFMEA upon receipt of a Customer engineering change.

The drawing / design model shall have all required information for the part,
including but not limited to:
- engineering/technical standards, specifications, and norms (plus any Review the design release date. Ensure it is consistent
deviations from those requirements); with temporary tool availability and with the program Verify the Supplier has the latest design model. Ensure Verify the Supplier has the latest design
- Geometric Dimensioning & Tolerancing (GD&T) / dimensional requirements; * Drawing / Design Model Initial design concept Prior to TKO timing. Ensure the latest mathematics are available the latest mathematics are available and are consistent model. Ensure the latest mathematics are
available and are consistent with the latest
- engineering Build Objectives or Table of Tolerances/Profiles; and are consistent with the latest release. Review the with the latest release. Verify the design status of all release. Verify the final released drawing
- identified special characteristics; proposed datum schemes and ensure they are sub-components. meets all requirements for closure.
- a list of sub-components (with part number, revision, and quantity). consistent with vehicle/part mating points.
Datum schemes shall be agreed upon by the applicable FCA representative and
be consistent with part mating/attachment points.
NV
* Engineering Standards Supplier Distribution
The Supplier shall have access to all FCA standards, through the applicable FCA (ESSD) - NAFTA
systems. The Supplier shall have a procedure that requires regular reviews to * BeStandard (ORANGE) - EMEA / LATAM
ensure they have the most recent released versions of the standards, and
requires communication to their various departments in the event of a revision *customer
Procedure for review of
standards Systemic Review for concurrence to the Requirements
update. If Supplier internal specifications or standards are referenced (e.g., on
the design model, on sub-component drawings, etc.), those standards must be
Design Model & clearly linked to the applicable FCA standard or specification.
1C Release

Supplier-responsible designs shall be approved by the FCA Engineer prior to
release. For NAFTA, the Design Acceptance Checklist (DAC) is required to be
completed by Steps 2, 3, and 5.
Verify the Engineer concurs with the latest released
design. For NAFTA, review the engineering Design
Acceptance document with the FCA Engineer at Step 2,
* Approved design Step 2 (Vehicle) Step 5 (Vehicle) Step 3, and Step 5 (or MR1, MR2, and PRC for
* Design Acceptance Checklist MR1 (Powertrain) PRC (Powertrain) Powertrain). Ensure corrective actions or risk
(DAC) - NAFTA mitigation activities are in place for any open issues.
Issues that receive a score of 1 (Job Stopper) or 2 (Job
Stopper Risk) should have corrective actions in place
before proceeding with Tooling Kickof.
Verify the Engineer concurs with the latest released
design. For NAFTA, review the engineering Design
Acceptance document with the FCA Engineer at Step 2, Ensure all open issues relating to design
Step 3, and Step 5 (or MR1, MR2, and PRC for and DAC, for NAFTA) are closed and the
Powertrain). Ensure corrective actions or risk FCA Engineer has approved the latest
mitigation activities are in place for any open issues.
Issues that receive a score of 1 (Job Stopper) or 2 (Job design release.
Stopper Risk) should have corrective actions in place
before proceeding with Tooling Kickof.

Design responsible Suppliers shall consider Design for Serviceability, which

ensures ease of disassembly of product with minimal cost and time. The * Service engineering design Initial design concept Prior to TKO Review serviceability requirements with Supplier and Review the design with the FCA Service engineer. Ensure no issues remain open
Supplier shall meet all applicable FCA standards for structure or serviceability approval FCA Engineering.
(e.g., CEP standards), with FCA Service Engineering approval of the design.

* ISO/TS-16949 cl. 7.2.1.1, 7.3.1.1, 7.3.2.3,

Special characteristics for the part and process shall be identified. These
include product or process characteristics that can afect safety, fit, form,
function, performance, regulation compliance, or subsequent part processing.
Characteristics that fall into this category include, but are not limited to:
Regulatory (Safety <S> / Emissions <E> / Homologation <H>, Report, PQC-S),
Functional (Qf), Important (Qi, Qd), torque and welding requirements,
characteristics identified as SPC points on the design model, and "legacy"
characteristics (diamonds <D> / stoplights, Qh, Qc, Q+, PQC X, CPC X). They
shall also be shown on the design model, in all applicable quality documents
(D/PFMEAs, Control Plan, work/inspection instructions, etc.), and included in I/S) - NAFTA
the Safe-Launch Plan, SQE Audit (7C), and Initial Process Study after the PDR
Stage 1. For NAFTA, all special characteristics shall be identified on the Part
Inspection Standard included in the Source Package, and approved by the FCA
Engineer and Plant Quality. NOTE 1: It is not mandatory that all parts have
special characteristics. NOTE 2: Special characteristics are not exclusively
dimensional, they can also include functional, material, appearance, etc.
Review the list of special characteristics (Product Card -
EMEA/LATAM or Part I/S - NAFTA) from the Source
* Drawing / Design Model
* List of Special Characteristics Package with the Supplier, FCA Engineer, and FCA Plant
Initial design concept Prior to TKO Quality. Ensure all special characteristics are included
* Part Inspection Standard (Part (dimensional, functional, appearance, etc.) in the
development of the Supplier's Control Plan and Safe-
Launch Plan.
Review latest design model against the list of special
characteristics, Control Plan, and Safe-Launch Plan and
ensure agreement with FCA Engineering and FCA Plant
Quality. Verify all special characteristics are included in
other applicable quality documents as they are
developed.
Verify all special characteristics are
included in the applicable quality
documents (especially Control Plan and
Safe-Launch Plan) and the Initial Process
Study.
7.3.3.1
* FCA US LLC Customer Specific Requirements
for ISO/TS-16949
* FCA Italy Customer Specific Requirements for
ISO/TS-16949
* EMEA / LATAM - Specifications series
9.01102/## about Characteristics Classification
and 9.01102/20 (Report Characteristics )
* CS.00071 Classification of Characteristics
* AIAG Statistical Process Control (SPC) Manual
* Performance Requirements (in this document)

* Production Demonstration Run (PDR) Tool Kit

Special If the part does not have special characteristics identified on the design model,
1D Characteristics the Supplier and Process Audit team shall select characteristics that afect Verify with the Supplier, FCA Engineering, and FCA At final PPR meeting before the Process Audit Use the selected characteristic list during
close tolerances, fit, function, finish, reliability, durability or characteristics * List of selected characteristics Final PPR before RE Process Audit Readiness Evaluation, select, with FCA Engineering and the SQE Audit (see 7C) and ensure the
afected by process parameters and/or characteristics that afect the Readiness Evaluation Plant Quality that the part or parts do not require
special characteristics. the Supplier, a list of characteristics to check during the Supplier follows the list for the Initial
successive/final process to include in the SQE Audit and process performance SQE Audit and Initial Process Study. Process Study (see 7B).
and capability studies.

For all fastener joints, the Supplier shall have a defined torque strategy in
place. For M6 and above, the Supplier shall develop a torque plus angle Review torque and angle strategy for all fastener joints, Review latest design model against the torque and
strategy unless explicitly told otherwise by an FCA Engineering representative. Verify torque and angle requirements are
The torque plus angle strategy shall include error or mistake proofing such as * Torque Strategy Technical Review Prior to TKO as required. Review planned error and mistake
proofing. angle strategy. being met on all fastener joints.
lock out features in the event the torque and angle requirements are not met,
etc.

The drawing or design model shall reflect the change level and revision level of Verify Supplier has the latest release. Ensure that as Verify Supplier has the latest release. Ensure that as
the part(s) undergoing the Process Audit. All applicable quality documents * Drawing / Design Model changes occur, appropriate modifications are made to changes occur, appropriate modifications are made to Verify Supplier has the latest release and
(including, but not limited to, the Process Flow Chart, D/PFMEA, Control Plan, * All applicable quality On-going program timing and other deliverables, as required. program timing and other deliverables, as required. that it matches the part undergoing
and all Instructions) shall also reflect the correct change level and revision documents Also verify appropriate risk mitigation activities are Also verify appropriate risk mitigation activities are PA/PDR. Verify all risk mitigation activities
planned when deliverables become late to their planned when deliverables become late to their have been successfully closed.
level. required milestones. required milestones.

* ISO/TS-16949, cl. 4.2.3.

The Supplier shall have a procedure for proper change management, including:
- receipt of FCA approval (Change Notice or OdM);
Change - notification to the Customer of any risk or impact on timing, program
1E Management milestones, tooling, or resources;
- updates of all applicable quality documents;
- removal of uncontrolled or out-of-date documents; * Change Management
- quarantine/disposition/obsolescence of out-of-date material (product procedure
produced prior to the engineering change); Systemic Review procedure for concurrence to requirements.
* Authorized engineering
- record or log of the first production shipment and retention of that data for change
traceability; documents
- and communication of changes to all applicable sub-tier suppliers. It is the
Tier 1 Supplier's responsibility to ensure the finished part is at the correct
change and revision level. NOTE: The Supplier shall not make any changes
without DOCUMENTED approval from FCA Engineering (i.e. voicemail, e-mail,
etc. are UNACCEPTABLE).

* FCA program timing (CPCP / GVD, GPD)

The Supplier shall have a Product Development Plan for the program that
includes the following:
- dates and timing for all key FCA milestones (such as design approval, Material
Required Dates (MRD), pilot builds, launch, etc.);
- planned and actual dates for all key FCA deliverables (such as the Process
Audit Readiness Evaluation, PA Process Evaluation visit, PDR Stage 1 and 2, Full
Approval (PPAP or Qualificazione), etc.);
- Risk Mitigation activities for any deliverables that are late / potentially late to
their required due dates.
Review the Supplier's plan for program timing. Ensure * FCA norm 07740 - EMEA / LATAM
they are aware of all key milestones, and that key
program deliverables are scheduled according to their
required milestones. Review specific dates for the Review and update the Supplier's plan for program
following: PA Readiness Evaluation, PV / Self- timing. Develop or review Risk Mitigation plans for any Ensure all Risk Mitigation plans are
* Product Development Plan Entire Program
Qualification Testing Start & Finish, PA Process deliverables that are or are expected to be late to their successfully closed.
Evaluation, Stage 1 PDR, Full Approval, and Stage 2 required due dates.
PDR. Develop or review Risk Mitigation plans for any
deliverables that are or are expected to be late to their
required due dates.

* FCA program timing (CPCP / GVD, GPD)

* FCA norm 07740 - EMEA / LATAM
Review the Tooling Kick-of date and ensure Review the Tooling Kick-of date and ensure
The Supplier's Product Development Plan shall include all details related to consistency with program deliverable timing. Ensure consistency with program deliverable timing. Ensure
tooling and tool construction. This includes: the timing allows for parts of of production tooling by the timing allows for parts of of production tooling by
Program - planned and actual dates for key tooling deliverables (such as Tooling Kick-Of the required build / milestone. Note that the Tooling the required build / milestone. Note that the Tooling
2A Management & (TKO), total tool construction time, Of Tool Not Of Process (OTNOP), Of Tool
Of Process (OTOP), etc.); * Product Development Plan
Kick-of date is the date that tools actually begin
construction (i.e., "cutting steel"). Once tools are
Kick-of date is the date that tools actually begin
construction (i.e., "cutting steel"). Once tools are Ensure all Risk Mitigation plans are
Timing - expected tooling and part status at each pilot build and pilot build stage; * Tooling Kick-of forms Entire Program kicked-of, follow their progress. Ensure toolmakers are kicked-of, follow their progress (updated every 2 successfully closed.
- Risk Mitigation activities for any deliverables that are late / potentially late to aware of the latest design changes. If tool completion weeks, at a minimum). Ensure toolmakers are aware of
their required due dates; timing changes, ensure adequate risk mitigation plans the latest design changes. If tool completion timing
- identification of the FCA TAG individual responsible for each tool (when are in place (as required). Note: for tooling followed by changes, ensure adequate risk mitigation plans are in
applicable). TAG, obtain status updates from the TAG place (as required). Note: for tooling followed by TAG,
representative. obtain status updates from the TAG representative.

The Supplier shall have access to the eSupplierConnect portal and support all
required FCA systems (e.g., MaPS, CQMS, SQP, NCT, eCIMS, etc.). They shall
have at least 2 fully trained individuals able to access each system. Contact Systemic Verify Supplier has appropriate resources and access to Customer systems.
information shall be current and updated.

The Supplier shall provide adequate resources to the program to ensure

deliverables and/or risk mitigation activities are completed per their required * Program contact list Systemic Review the Supplier's team and resources devoted to the program. Are enough resources given? Is the commitment of the members adequate? Are the
dates. obligations respected? Is the contact list complete?

A Process Flow Diagram is required for all parts. It shall:

- reflect the entire process, beginning at the receiving area and continuing
through shipping;
- include all labeling, product storage, rework/repair, and gaging/inspection
areas, whether they are a part of the primary process or of-line (secondary)
processes;
- identify stations which measure special characteristics and/or contribute to
significant nonconformances;
- ensure that process and material flow is designed to avoid missing of
operations or mixing of parts with similar products;
- include the processing sequence, method, and equipment used at each
station (including inspection and repair/rework stations), with unique machine
Process Flow numbers identified;
2B Diagram - indicate the flow of repaired or reworked material back into the normal
process to ensure the parts pass through all required controls for all rework /
repair stations;
- identify the number of operators required per station (including float
operators, as applicable);
- indicate any bottleneck or constraint operations.
Ensure the Process Flow Diagram, floor plan, and work
station layout reflect the planned process. All
processes and sub-processes shall be included, from
raw material receiving to final assembly shipping,
including rework/scrap areas. Verify that all are at the
Process Audit Process latest
* Process Flow Diagram Technical Review level of the process. Ensure unique machine or
Evaluation tool numbers are included in the Process Flow. Ensure
all rework/repair operations have been included.
Review operators required for the process. Ensure
suspected bottleneck operation / constraint is
identified.
Ensure the Process Flow Diagram, floor plan, and work
station layout reflect the planned process. All
processes and sub-processes shall be included, from
raw material receiving to final assembly shipping,
including rework/scrap areas. Verify that all are at the
latest level of the process. Ensure unique machine or
tool numbers are included in the Process Flow. Ensure
all rework/repair operations have been included.
Review operators required for the process. Ensure
suspected bottleneck operation / constraint is
identified.
Verify by witnessing on the manufacturing
floor that the Process Flow Diagram and
Work Station Layout reflect the actual
process and that facilities, equipment,
lighting, etc. are adequate. Verify actual
tool/machine numbers match the Process
Flow Diagram. Verify rework/repair
processes follow the identified process
flow. Verify number of operators
performing the PA/PDR match the Process
Flow Diagram. Verify bottleneck or
constraint operation.

A work station layout or manufacturing floor plan shall be available that details
the following: operation to operation flow, all manufacturing / inspection * Work station layout / Process Audit Process Review work station layout and manufacturing floor Review work station layout and manufacturing floor Verify actual plant and process layout
equipment and tooling used in the process, identified material storage manufacturing floor plan Technical Review Evaluation plan. plan. match the documentation.
locations (for WIP / bufers, nonconforming material / scrap, rework / repair,
and raw material / sub-components).
* Potential Failure Mode & Efects Analysis
manual (4th Edition) AIAG
Initial review of PFMEA. Ensure it was developed taking * ISO/TS-16949 7.3.3.2
into account the Master PFMEA and lessons learned Ensure PFMEA has been updated to latest * Supplier PFMEA Audit Summary form
A Process Failure Mode & Efects Analysis (PFMEA) shall be available for all * Process FMEA from previous programs and action plans exist for design revision level. Review using FIAT * FCA Norm 00271 - EMEA / LATAM
parts. It shall be created using all Customer guidelines and required FMEA * Supplier PFMEA Audit Technical Review Prior to TKO items with the highest risk. Verify items with a Severity Review PFMEA as changes occur to design. Ensure norm 00271 to verify document is
reference manuals. The PFMEA shall be reviewed by the SQE and rated adherence to FIAT norm 00271. acceptable. Verify PFMEA has been
"Green" per the "Supplier PFMEA Audit Summary" form. Summary greater than or equal to 8 (or per FCA requirements, if updated to account for most recent version
more stringent) are adequately error-proofed or of Master PFMEA.
actions are taken to minimize the severity via design.

* Potential Failure Mode & Efects Analysis

manual (4th Edition) AIAG
The Supplier shall have a procedure for development of PFMEAs and records * ISO/TS-16949 7.3.3.2
that ensure all PFMEAs are periodically reviewed and evaluated for continuous * FCA Norm 00271 - EMEA / LATAM
improvement of failure modes. Failure modes identified as the highest risk
2C Process FMEA shall be addressed first. The procedure shall also include: * PFMEA review / evaluation
- determination of severity, occurrence, and detection values; procedure & records Systemic Review procedure for concurrence to requirements.
- regular reviews and updates for lessons learned (e.g., yardholds, field
campaigns) and internal / external benchmarking;
- updates of the PFMEA upon receipt of a Customer engineering change notice
(as necessary).

* Potential Failure Mode & Efects Analysis

Potential causes and efects of "Buzz / Squeak / Rattle" and "Noise / Vibration / manual (4th Edition) AIAG
* Process FMEA * ISO/TS-16949 7.3.3.2
Harshness" (BSR/NVH) shall be addressed in the FMEAs, Control Plan, and Test * Control Plan Ensure the Supplier's PFMEA has incorporated Verify BSR/NVH causes and efects have
Plan. Analyses shall include evaluations of interactions with mating parts to Process Audit Review BSR/NVH test results. Update PFMEA, Control * Supplier PFMEA Audit Summary form
reduce, eliminate, and/or monitor objectionable BSR or NVH characteristics. It * DVP&R - NAFTA Technical Review Readiness Evaluation potential causes of BSR/NVH. Ensure initial control Plan, and test plans accordingly. been adequately addressed into the * FCA Norm 00271 - EMEA / LATAM
is the Supplier’s responsibility to ensure their parts do not exhibit any * AQF/PI test plans - EMEA / plans and DV test plans include appropriate tests. PFMEA, Control Plan, and test plans.
BSR/NVH conditions within their environments. LATAM

The Supplier shall have a complete list of all dies/tooling, equipment, and
gages used in the process. This list shall indicate ownership of the tooling,
unique identification numbers, and location of the item. The SQE shall verify
the presence of all tooling (including number of cavities), equipment, and
gages identified on the list. Tooling and equipment, when not in use, shall be
properly identified and stored to avoid confusion in the flow management of
components/products being manufactured. There shall be a Supplier Tool
Record which lists all FCA-owned tooling, with tooling number and location.
* Supplier Tool Record
* List of Tooling and Equipment
Verify that FCA tooling & equipment (complete or
under construction) is consistent with that which was
determined needed during the sourcing phase. Any
Issuance of the OTOP modifications (e.g., more tools required, some tools
Contract not needed/built, etc.) with respect to which was
declared during sourcing shall be promptly reported to
the Buyer. Review the Supplier's plan / procedure for
release of tools and equipment to the production floor.
Verify that FCA tooling & equipment (complete or
under construction) is consistent with that which was
determined needed during the sourcing phase. Any
modifications (e.g., more tools required, some tools Verify completed tooling matches FCA
not needed/built, etc.) with respect to which was records and Supplier's tooling list.
declared during sourcing shall be promptly reported to
the Buyer. Review the Supplier's plan / procedure for
release of tools and equipment to the production floor.

* CG Business Processes - Part Requirements for

VP & PS Pilot Builds - NAFTA
Review the Supplier's plan for delivery of parts for the
The SQE shall verify die/tooling, equipment, and gage status in terms of: applicable Pilot builds. Ensure it includes quantities Verify the Process Audit Process Evaluation
timing (completion, try-out, sampling, etc.), function, and part availability for Review the Supplier's plan for delivery of parts from and timing (for each phase). Review tooling and PDR are run on homeline with
key program milestones. Tools and equipment shall be built following all * AQR Process Audit Process temporary tools. Ensure quantities and timing are construction status. Ensure parts of of production production tooling. If this is a Risk
requirements in the AQR, as applicable. The Process Audit Readiness and * "Prototype" part delivery plan Tooling Kick-Of Evaluation included. Make sure the plan includes evaluation of tools will be available for the required milestone (e.g., Mitigation Run, ensure any tooling being
* Pilot build delivery plan part quality (measurement of special characteristics, VP or Pre-Pilot). If not, review the risk mitigation plan,
Process Evaluations and PDR shall be run on finished production tools using etc.). especially if temporary tooling will need to be used used can support volumes for launch and
definitive production processes. instead. Verify Supplier has included all applicable production until final tooling is complete.
requirements from the AQR.

* CG Business Processes - Readiness of Design -

All FCA-owned tooling shall have a Tooling Kick-of from the appropriate FCA To Start Supplier Tooling Kick-Of - NAFTA
Tooling representatives. Tooling developed/followed by the FCA Tooling Analysis Group * Approved Tooling Kick-Of Tooling Kick-Of Tooling Kick-Of Review plan for TKO. Review TKO status and form. N/A * TAG Tooling Kick-Of - EMEA/LATAM
2D Development & (TAG) shall have a tooling sign-of from the applicable TAG representative.
Pilot Parts
* FCA contract Terms & Conditions
* FGP norm 24 - EMEA / LATAM

FCA-owned tooling, equipment, and gages shall be identified and marked per
FCA requirements. It shall be used only for the production of FCA products. Tooling Kick-Of Process Audit Process N/A Review requirements for Customer tools with the Verify tools are marked per FGP norm 24.
Tools shall meet the requirements in FGP procedure 24. Evaluation Supplier to ensure they understand.

Review the list of component suppliers, raw material

The Supplier shall have a process for evaluating the risk of each purchased sub- suppliers, and tool makers that the Supplier will be
component and raw material used in the part. The Supplier shall also have a using. Ensure all sub-tier suppliers have been approved
process for conducting Process Planning Reviews, Process Audits, and * Sub-component risk Process Audit and the appropriate risk assessments have been done Review status of all high and medium risk sub-
Production Demonstration Runs (or use equivalent tools) on sub-components * Sub-component PPR/PA/PDR Technical Review on the components or materials, and that tool makers components and materials. If any are late, ensure See item 7D
that are not considered "Low" risk. In addition, the Supplier shall have a plan procedures and plan Readiness Evaluation are properly certified. Review that the Supplier's timing appropriate risk mitigation activities are in place.
for performing these activities in order to support FCA's pilot builds and other for Process Audits / PDRs and PPAP of the sub-
milestones with the required level of approved parts. components supports overall program timing, and
check the status of each component and material.

Sub-Component
2E Development Review preliminary Supply Chain diagram for potential
The Supplier shall have available a Supply Chain diagram. The diagram shall
outline the entire Supply Chain, beginning with raw materials and ending with supply concerns (e.g., long distances, multiple border
the FCA or FCA-designated facility. All secondary processes and/or services * Supply Chain diagram PPR Kick-Of Process Audit Process crossings, etc.). If potential supply issues or risks (e.g., Update Supply Chain diagram and back-up plans / risk Verify final Supply Chain diagram.
Evaluation long distance) exist, ensure that appropriate risk mitigation activities as necessary.
(e.g. plating, heat treating, etc.) shall be shown, including of-site storage and
shipping locations. mitigation activities are in place (e.g., safety stock,
expediting, etc.)

For sub-tier suppliers and sub-components, the supply of sub-components Review preliminary Supply Chain diagram for potential
shall be ensured through backup plans; e.g., safety stock, alternate supply concerns (e.g., long distances, multiple border
transportation, availability of alternate PPAP approved sub-components, etc. Process Audit Process crossings, etc.). If potential supply issues or risks (e.g., Update Supply Chain diagram and back-up plans / risk Verify back-up plans for critical
NOTE: switching sub-tier suppliers requires notification and approval from FCA * Sub-component backup plans PPR Kick-Of Evaluation long distance) exist, ensure that appropriate risk mitigation activities as necessary. components.
(via
A appropriate
Control system
Plan shall or process,
be available for such as the
all parts. Forever
It shall Requirements)
be created using allatFCA
all mitigation activities are in place (e.g., safety stock,
times.
guidelines and the AIAG APQP & Control Plan manual. The SQE shall review the expediting, etc.)
content of the Control Plan and determine acceptability. The Control Plan
shall: * Advanced Product Quality Planning & Control
- include all process stages, from incoming to labelling and shipping; Plan manual (2nd Edition)
- use the Process FMEA in creation of the Control Plan, with emphasis placed * FCA norm 9.01102 - EMEA / LATAM
Regularly review the status and content of the * ISO/TS-16949 7.5.1.1
on special characteristics; Supplier's Control Plan, both for Prototype (if
- ensure numbers and controls match PFMEA and Process Flow Chart; * ISO/TS-16949 App. A
applicable) and Production processes. Verify the Review all phases of the control plan. Ensure it is
- include all special characteristics and corresponding classifications and
symbols; * Control Plan After source selection Process Audit Process linkage between the Process Flow Diagram, PFMEA, updated as changes occur to the part or process, and Verify Control Plan meets all requirements.
- ensure characteristic classification is compliant with the technical Evaluation and Control Plan. Ensure controls are adequate and as changes occur to the Process Flow Chart and
match those described in the Design and Process PFMEA.
specifications and/or preventive analysis performed on the product when FMEAs. Verify that the Control Plan is updated to the
requested (FMEA, DOE, etc.); latest design revision level.
- include all applicable process control parameters;
- include suitable frequencies and sampling sizes;
- be updated to the latest CID/EWO/ODM level;
- ensure updating of the control methods/conditions with the evolution of the
referring documents (e.g., DFMEA, PFMEA, Family PFMEA, etc.); * Advanced Product Quality Planning & Control
The SQEevidence
- show shall verify
thatthat
it isthe Supplier
a “living” is following
document the controls
subject as review.
to regular listed in the Review the Control Plan against the actual Plan manual (2nd Edition)
Control Plan, and that frequency, sample sizes, measurement methods, * Control Plan process. For NAFTA, make sure the Control * FCA norm 9.01102 - EMEA / LATAM
Process Audit Process Audit Process N/A Verify the Supplier is incorporating controls into the * ISO/TS-16949 7.5.1.1
equipment recording, reaction plans, etc. are adequate. For NAFTA, the * Control Plan Process Audit Plan is "Green" per the Control Plan
3A Control Plan Control Plan shall be "Green" per the "Control Plan Process Audit Checklist" Checklist - NAFTA
Readiness Evaluation Evaluation process as it is developed.
Process Audit document. Ensure resources * ISO/TS-16949 App. A
form. dedicated to the controls are adequate.

* Advanced Product Quality Planning & Control

The control frequencies, sample sizes and measurement methods shall be Review high risk items on the DFMEA and PFMEA. Plan manual (2nd Edition)
based upon the efect of the characteristic on the functionality of the product Process Audit Process Ensure that corresponding controls on the Control Plan As changes to the DFMEA and PFMEA occur, ensure Verify that the team agrees with Control * FCA norm 9.01102 - EMEA / LATAM
as defined by preliminary analysis (e.g., DFMEA, PFMEA) and process stability. * Control Plan After source selection reflect higher sample sizes and frequencies than lower controls in the Control Plan reflect the risk of the Plan sample sizes and frequencies for high
Higher risk items on the FMEAs shall have correspondingly higher sample Evaluation risk items. Ensure the team agrees that controls on changed items. risk items. * ISO/TS-16949 7.5.1.1
sizes/frequencies. high risk items are adequate. * ISO/TS-16949 App. A
3A

When inspections are done "per lot", lot size shall not exceed one shift or one
production run, whichever is smaller. This includes incoming inspections on * Control Plan Systemic N/A N/A Verify that any inspections done "per lot"
sub-components, as well as in-process inspections and inspections on final do not exceed one shift or production run.
assemblies.
Ensure Supplier plans for rework / repair parts to go Ensure Supplier plans for rework / repair parts to go Verify rework/repair parts do go through
Repair/rework parts shall pass through controls equal to or exceeding those of Process Audit Process
the primary production line. * Control Plan After source selection Evaluation through controls equivalent to or better than the through controls equivalent to or better than the controls equivalent to or better than the
primary line. primary line. primary line.
* Advanced Product Quality Planning & Control
Plan manual (2nd Edition)
* FCA norm 9.01102 - EMEA / LATAM
The Supplier shall have a plan for Incoming Material Certification / Inspection * ISO/TS-16949 7.5.1.1
for all purchased components and raw materials. Sub-tier suppliers may be * ISO/TS-16949 App. A
placed on Self-Qualification (i.e., "dock-to-stock") if they have quality system Review the Supplier's plan for certification of incoming Verify that all Self-Qualified sub-tier
certification (e.g., ISO/TS-16949, ISO 9001), have acceptable quality
performance, and an approved Process Audit and PDR for that component * Incoming Inspection Plan and outgoing material. Review list of sub-tier suppliers suppliers have Process Audit approved
(see Sub-tier Approval); the Tier 1 Supplier shall have records of all of these (Control Plan) After source selection Process Audit Process who are planned to have Self-Qualification status; Review and update plans for Self-Qualified and non- components and acceptable quality
* Incoming Inspection Results Evaluation verify they have acceptable quality performance and qualified sub-tier suppliers. performance. Verify Tier 1 Supplier is
items. When it is necessary to purchase from non-qualified or unapproved * Self-Qualification procedures appropriate Process Audit activities are planned. following the inspection plan for non-
sub-tier suppliers, efective controls, using an adequate sampling plan, shall be Review plans for non-qualified sub-tier suppliers. qualified sub-tier supplier components.
exercised both in the Incoming Inspection area and the manufacturing process
to prevent/block the use of nonconforming parts or raw material. Inspection
results and records shall be available for review by the customer at all times.

Self-Qualification status on sub-tier suppliers shall be removed when

nonconformances occur. Details for re-acquiring Self-Qualification status shall
be defined, and require a minimum of three previous, consecutive, defect-free
shipments. A method of identifying parts from a Self-Qualified sub-tier
supplier shall be defined and appear on the material shipping documents, * Self-Qualification procedures Systemic Review procedure for concurrence to requirements.
product identification sheet, and on the package. While Self-Qualification
status is suspended or withdrawn, the Tier 1 Supplier shall implement full
incoming inspection on material from that sub-tier, with increased sample
sizes, frequencies, etc.
Incoming &
3B Outgoing
Inspection * Advanced Product Quality Planning & Control
When applicable, Incoming Inspection sampling plans shall be included in the Plan manual (2nd Edition)
Witness and verify that the Tier 1 Supplier * FCA norm 9.01102 - EMEA / LATAM
Control Plan with adequate frequencies, sample sizes, and measurement is performing inspections at the listed
methods. Inspection frequency, sample size, and measurement method shall Review incoming inspection plan and control plan. * ISO/TS-16949 7.5.1.1
be determined based upon risk level of the sub-component (e.g., per the * Control Plan After source selection Process Audit Process Review planned inspection frequencies, sample sizes, Review and update control plan as necessary. frequencies and sample sizes, using the * ISO/TS-16949 App. A
PFMEA), importance of the characteristic (e.g., Safety/Report, other special, Evaluation and measurement methods to ensure adequacy. agreed upon measurement methods.
Verify that the audits are random and have
etc.), and historical quality performance of the sub-tier supplier. Audits shall be appropriate analysis of the results.
random, with statistical analysis of results (as applicable).

Computerized systems used to manage incoming and outgoing product

(inspection, production/lot control, shipping, etc.) shall have backups in case Systemic Review computerized systems and verify backups are in place.
the primary system fails.
* Advanced Product Quality Planning & Control
Plan manual (2nd Edition)
The Supplier shall have an acceptable Outgoing Material Inspection plan (or * FCA norm 9.01102 - EMEA / LATAM
Product Audit Plan) that includes adequate outgoing inspection frequencies, Witness and verify that the Tier 1 Supplier * ISO/TS-16949 7.5.1.1
sample sizes, and measurement methods and documented in the Control Plan. is performing inspections at the listed * ISO/TS-16949 App. A
Inspection frequency, sample size, and measurement method shall be Review outgoing inspection plan and control plan. frequencies and sample sizes, using the
determined based upon risk level (e.g., per the PFMEA) and importance of the * Control Plan Process Audit Process Review planned inspection frequencies, sample sizes, agreed upon measurement methods.
characteristic (e.g., Safety/Report, other special, etc.). Audits shall be random, * Nonconformance reaction plans After source selection Evaluation and measurement methods to ensure adequacy. Review and update control plan as necessary. Verify that the audits are random and have
with statistical analysis of results (as applicable). The Supplier shall have Review nonconformance reaction plans. appropriate analysis of the results. Witness
reaction plans in place in the event a nonconformance is detected, which a demonstration of nonconformance
includes proper notification of FCA when the potential exists that reaction plans.
nonconforming material was shipped.

* FCA US LLC Customer Specific Requirements

for ISO/TS-16949 cl. 4.12.2
The Supplier shall have a process for Error and Mistake Proofing which * Error and Mistake Proofing Verify all planned Error and Mistake
describes the development, implementation, use, and maintenance of Error
and Mistake Proofing within the organization. The process shall include the process Proofing has been implemented. Witness
procedure for creation of Verification samples for all failure modes identified in * Error and Mistake Proofing Process Audit Process Review the Error and Mistake Proofing process and Review and update the Error and Mistake Proofing plan the Error and Mistake Proofing Verification
Verification Audit procedures, Technical Review plan. Review the plan for creation of Verification Audit prior to starting the Stage 1 PDR.
the Design and Process FMEAs and use of those samples with the Error and instructions, checklist Evaluation Samples. as required. Ensure that all Verification Samples are
Mistake Proofing Verification Audit to ensure the proper functioning of Error * DFMEA detected correctly or prevent manufacture
and Mistake Proofing. During the Process Audit, all Verification Samples shall
be run through the process and successfully detected as defective. * PFMEA of the defect.

Review plan and ensure all items on the D/PFMEAs

Error/Mistake Proofing is required for all items identified in the Design and
Process FMEAs with a severity of 8 or higher, as well as for all identified special ** DFMEA
PFMEA Technical Review Process Audit Process with severity of 8 or higher, as well as all special
Evaluation characteristics, have adequate Error and Mistake
Review and update the Error and Mistake Proofing plan Verify all planned Error and Mistake
as required. Proofing has been implemented.
characteristics (or per FCA requirements, if more stringent).
Proofing planned.

All Verification samples shall be clearly marked, labeled, and controlled to Prior to Process Audit Process Audit Process Ensure adequate storage and handling of Verification Ensure adequate storage and handling of Verification Verify all Verification Samples are properly
prevent mixing with production materials. They shall be stored separate from identified and stored to prevent accidental
WIP or finished product in a clearly marked container or designated area. Readiness Evaluation Evaluation Samples is planned. Samples is planned. mixing with production parts.

Line or station lock out shall be implemented at all process steps to prevent During the Error and Mistake Proofing
failed operations from proceeding to a subsequent station or into finished Review the Error and Mistake Proofing process and Verification Audit, ensure line and station
product. Audible and visual indicators shall notify of the failed operation. plan. Ensure Supplier has planned appropriate lock-outs, as well as audible and visual
Corrective actions shall be implemented prior to restarting the line or station. *contingency
Error and Mistake Proofing
/ backup plans Tooling Kick-Of Process Audit Process line/station lock out and audible/visual indicators. Review and update the Error and Mistake Proofing plan indicators, are working correctly each time
The Supplier shall have a contingency plan in the event the production Mistake Evaluation Ensure the Supplier has an adequate back-up plan in as required. a sample is run. This should be a part of
Proofing is not operable. A visual and/or audible alert shall signify the Mistake the event that applicable Error and Mistake Proofing the Supplier's checklist, as well. Verify the
Proofing is inoperable. The plan shall include notification to FCA via the fails Supplier's backup plan is robust and
applicable system. functioning.

Error and Mistake Proofing software shall be tested for all known failures and Prior to Process Audit Process Audit Process Review the Error and Mistake Proofing process and Review and update the Error and Mistake Proofing plan Verify Error and Mistake Proofing software
during the Error and Mistake Proofing
bypass scenarios. Readiness Evaluation Evaluation plan. as required.
Verification Audit.

Final verification ("end-of-line") stations shall:

- ensure parts cannot skip this station; Verify EOL tester during the Error and
- leave a unique mark showing the part successfully passed through; Tooling Kick-Of Process Audit Process Review the Error and Mistake Proofing process and
plan. Ensure Supplier has planned appropriate Review and update the Error and Mistake Proofing plan Mistake Proofing Verification Audit. This
Error & Mistake - verify the end item is correct and complete and ensure all components are Evaluation functions for the End of Line (EOL) tester, if applicable. as required. should also include parts that are known
3C Proofing present (verifying components are in the machine prior to assembly and acceptable, as well.
assuming they are on the finished assembly is insufficient)

Error or Mistake Proofing shall verify:

- all functions, eforts, and travel 100%;
- sub-component selection 100%;
- all cylinders applying staking or components for full stroke;
- flow, amount, and location of critical lubrication and adhesive points, liquids,
and gases;
- leak testing for all liquids and gases 100%;
- proper assembly and packaging when machines accommodate multiple parts Process Audit Process Review the Error and Mistake Proofing process and Review and update the Error and Mistake Proofing plan Verify Error and Mistake Proofing
(right/left, front/rear, etc.); Tooling Kick-Of Evaluation plan. Ensure Supplier has planned to cover all as required. requirements are covered during the Error
- loose foreign objects are prevented from entering the assembly area; applicable requirements. and Mistake Proofing Verification Audit.
- continuity and function on electrical components and connections 100%,
with line stop / lockout if continuity is failed;
- sequential sensing is used when the process includes independent cells
making up one process flow;
- torque and angle requirements for all required fasteners, with automatic line
lock-out if those requirements are not met (see 1D).

Electrical terminal contact for in-process manufacturing (harness assembly,

engine testing, device testing, etc.) shall meet the following:
- pogo pins shall not violate the contact area of the terminal(s) being tested;
- pogo pins shall be maintained and inspected regularly;
- the test fixture shall align the connector to the test fixture prior to
engagement of the pogo pins;
- when pogo pin access is not provided and spring member contact is the only Process Audit Process Review the Error and Mistake Proofing process and Review and update the Error and Mistake Proofing plan Verify Error and Mistake Proofing
option, the probe used to contact the terminal spring member shall be smaller Tooling Kick-Of Evaluation plan. Ensure Supplier has planned to cover all as required. requirements are covered during the Error
in thickness than the minimum blade thickness (including tolerances) of the applicable requirements. and Mistake Proofing Verification Audit.
terminal being tested. If round pin terminals are being tested, the male pin
probe shall be smaller than the minimum diameter (including tolerances) of
the pin;
- the depth of insertion of the probe shall be the minimum necessary for
electrical contact testing.

* ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.3-8.2.4.2

The Supplier shall have a process that ensures Master samples, gages, Verify that all Master samples, gages,
measuring devices, and test equipment are available for use (at the inspection * Gage handling process Review Supplier's process for gage, measuring device, As gages and equipment become available, ensure measuring devices, etc. are identified and
station, when required), adequately identified, and properly handled and When design is Prior to Process Audit test equipment, et. al. handling. Ensure planned
stored when not in use. Master samples used to verify the operating condition ** Control Plan
Gage work instructions finalized Readiness Evaluation storage locations are adequate to protect the they are identified, stored, etc. as per the gage
handling plan.
stored appropriately. Ensure Master
samples are used according to frequencies
of gages shall be used according to the frequencies set in either the Control equipment from damage. established in the Control Plan.
Plan or gage work instructions.

* FCA norm 70100/00 - EMEA / LATAM

* FCA procedure 71018 - EMEA / LATAM
* FCA procedure 1 - EMEA / LATAM
Gages and measuring devices shall be appropriate to the requirements of * Measurement Systems Analysis manual (4th
drawings, regulations and importance of the characteristics (as defined by the Edition) - NAFTA
characteristic classification, Design or Process FMEA, etc.). All Special * FCA US LLC GEDOC001 (ME) - NAFTA
Characteristics (see 1D) require variable gages, unless otherwise agreed to by Review planned gages and measuring devices for * ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.3-8.2.4.2
FCA. FCA-owned gages shall meet all FCA requirements, including gage adequacy and appropriateness for measuring the Review status and timing of gages and equipment, and Verify gages are at the latest design level.
requirements listed in the AQR; when required by FCA, gages shall be built to
reflect the part in actual vehicle position. The Supplier shall have a process for When design is Prior to Process Audit characteristic (special characteristics require variable ensure they are at the latest revision level. Review (and Confirm all gages and measuring devices
validating gages and measuring devices prior to release on the manufacturing * Gage R&R studies finalized Readiness Evaluation data unless otherwise agreed to by FCA). Determine witness, if able) Gage R&R studies performed at the
which gages, if any, need to be built to reflect the part gage manufacturer and at the Supplier. Ensure planned have acceptable R&R results. Verify AQR
floor, including Repeatability and Reproducibility (R&R) studies for all. For new in vehicle position. Review AQR and identify gage and gages include AQR requirements. requirements for gages have been met.
parts and processes, gage R&R as a percentage of Total Tolerance shall be measuring device requirements.
used; for process improvements, gage R&R as a percentage of Total Variation
shall be used. Acceptable gage R&R shall be <10% in either case. A gage R&R
between 10% and 30% shall require approval from the FCA team before being
released for production. R&R results > 30% are unacceptable.

Gages & Measuring

3D Devices
When gages or measuring devices are used for 100% inspection, the tolerances When design is Prior to Process Audit Identify gages that will be used for 100% inspection. Verify gages used for 100% inspection have
shall be reduced by the extent of the gage R&R to ensure out-of-specification * Gage R&R studies finalized Readiness Evaluation Identify gages that will be used for 100% inspection. tolerances reduced by the extent of the
parts are not passed. R&R.
Identify planned resources for inspection and control
The Supplier shall have sufficient resources (gages, measuring devices, and Technical Review Prior to Process Audit (gages, equipment, personnel). Determine need for Review and update planned resources, as necessary. Verify planned resources have been
personnel) to carry out the controls listed on the Control Plan. Readiness Evaluation additional resources, if any. acquired and allocated.

* FCA norm 70100/00 - EMEA / LATAM

* FCA procedure 71018 - EMEA / LATAM
The Supplier shall have a process or system for calibration of gages and * FCA procedure 1 - EMEA / LATAM
measuring devices. This process shall: * Measurement Systems Analysis manual (4th
- ensure all gages, gage blocks, reference samples, and test equipment are Edition) - NAFTA
calibrated, traceable to a known source and national standard, and reflect the * FCA US LLC GEDOC001 (ME) - NAFTA
last calibration and expiration dates; * ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.3-8.2.4.2
- ensure metrological traceability and calibration expiration dates are clearly Verify all gages and measuring devices to
marked (via calibration stickers, color code, etc.) on applicable gages, * Calibration procedures and be used are calibrated and not expired.
equipment, etc.; work instructions Systemic Review Supplier's calibration and re-calibration Ensure gages and measuring devices are calibrated as Review traceability and witness a
- include a re-calibration schedule that includes all gages and measuring * Re-calibration schedule and process, along with reaction plans. they become available. demonstration of the re-calibration process
devices, with detailed procedures or work instructions for performing the re- procedures and reaction plan for past due items.
calibration;
- ensure re-calibration is done per the schedule, with a reaction plan and
containment for any equipment that is past-due;
- ensure the continuance of controls and inspections while the primary
equipment is undergoing re-calibration.

3rd party sources used for gage and test equipment calibration shall be * ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.4-8.2.4.2
evaluated by the Supplier and be certified to ISO/IEC 17025. Systemic Identify 3rd Parties used for calibrations and verify ISO/IEC 17025 certification. * ISO/IEC 17025
* PPA Manual
* FCA norm 07171 - EMEA / LATAM

The SQE shall review the Supplier's Safe-Launch Plan (SLP), included on the
Control Plan, for ensuring parts meet specifications during the pilot and launch
phases. This includes inspections and controls over and above those of
standard production (e.g., increased frequencies, sample sizes, etc.) for special,
BSR/NVH, and other required characteristics. The SQE shall also review any Review the Supplier's initial SLP. Ensure all special
data collected for SLP prior to the Process Audit and stations or inspection Job 1 + 90 days characteristics are included. Identify whether the
Safe Launch areas used for the activity. Stations or inspection areas used for SLP activities * Safe-Launch Plan Prior to VP (Vehicle) (Vehicle) standard duration will be followed or if it will be Review initial SLP data. Verify the Supplier
3E Activities shall be considered part of the normal process (i.e., included in the Control * Data from previous SLP Prior to Gamma SoP + 90 days extended. Identify if the part/program will follow Review the Safe-Launch Plan and update as necessary. is following the plan for all shipments
Plan), and have adequate lighting (at least equivalent to that used by the shipments (Powertrain) (Powertrain) launch containment (such as Launch Risk Mitigation). through the specified duration.
Customer's CPA inspection area), inspection instructions, boundary samples, Identify method of identification of parts for SLP.
etc. Duration of SLP is Job 1 plus 90 days (new programs) or first shipment plus
90 days (all other situations). If a defect is discovered, the SLP duration shall be
repeated in full. Parts inspected as part of the Safe-Launch activities shall be
identified per the Customer's requirements.

* Statistical Process Control manual (2nd

Edition) AIAG - NAFTA
The Supplier shall be responsible for maintaining manufacturing process * FCA norm 9.01102/08 - Statistical Process
performance/capability and have a procedure for the detection of process Control, Guide Lines - EMEA / LATAM
drift, degradation, and out-of-control measurements and immediate corrective * ISO/TS-16949 cl. 8.2.3 - 8.2.3.1
action on the process. Data recording methods shall be suitable for the checks * Control charts Review the Supplier's procedures for process monitoring and methods of data collection and reaction plans for out-of-control or nonconforming results.
being performed and control limits used shall be calculated based on the * Process monitoring results & Review actual data and results from other processes at the facility to verify conformance to the procedures. Ensure the Supplier has plans and forms in
data Systemic place for the new process and records data during the Process Audit.
requirements in the Statistical Process Control manual. The Supplier shall have * Corrective actions for out-of- Review which supporting processes are required for the part (e.g., painting, plating, heat treat, surface treatments for corrosion protection, etc.). What is
a process for the easy identification of conforming products produced (lot control items the Supplier's plan for management and control of these processes? Are the specifications clearly defined?
breaker, control charts, etc.). Nonconforming, out-of-control conditions, or
special causes of variation shall be clearly identified, documented and linked to
a corrective action process that is responsive to the operator.

* Statistical Process Control manual (2nd

Process/machine parameters subject to significant variation over time (e.g. * Process monitoring results & Review the Supplier's procedures for process monitoring and methods of data collection and reaction plans for out-of-control or nonconforming results. Edition) AIAG - NAFTA
temperatures, hold times, speed, pressures, etc.) shall be systematically data Systemic Review actual data and results from other processes at the facility to verify conformance to the procedures. Ensure the Supplier has plans and forms in * FCA norm 9.01102/08 - Statistical Process
monitored with respect to set tolerances. They shall have controllers with * Corrective actions for out-of- place for the new process and records data during the Process Audit. Control, Guide Lines - EMEA / LATAM
closed loop feedback systems maintaining established process limits. control items * ISO/TS-16949 cl. 8.2.3 - 8.2.3.1

* ISO/TS-16949 cl. 7.5.1.2, 8.2.3 - 8.2.3.1

The Supplier shall have all required technical documentation (work
instructions, Control Plan, SPC charts, inspection logbooks, etc.) available and Ensure technical documentation is
accessible at the applicable work stations. There shall be visual displays of
4A Process Monitoring process performance (e.g., FTC, scrap, machine downtime, etc.) visible and up- * Process performance results Systemic N/A Review draft documentation as it becomes available. available at applicable work stations.
to-date on the manufacturing floor. The Supplier shall have process and plans Review visual displays of process
performance, with metrics and targets.
performance targets identified for each metric, with plans and progress
towards achieving the targets documented and tracked.

The Supplier shall have a process for creation, approval, and proper storage
and handling of Boundary Samples or Appearance Manual used for inspection.
Approval shall include Plant Perceived Quality (CPA), plus other appropriate
FCA representatives (SQ, Engineering, Corporate Quality, etc.). This process * Boundary Sample / Appearance Systemic Review Suppliers process for Boundary Samples for conformance to requirements.
shall also include periodic review of Boundary Samples (minimum every 3 Manual procedure
months, or as agreed to by FCA) to ensure acceptability. When requested,
copies of Boundary Samples shall be made available to the FCA facility and
Quality personnel.

When used for inspection, Boundary Samples or Appearance Manuals shall be

available at the inspection station and accessible to the inspection operator. Review Boundary Samples to ensure they
They shall be clearly identified with: part name, part number, date that it is
valid until, description of its purpose, and appropriate Supplier management * Appearance Manual Process Audit Process Audit Process Identify what Boundary Samples will be needed for the Identify what Boundary Samples will be needed for the are properly identified, handled, and
signature (and FCA signature, as required). When not in use, Boundary Readiness Evaluation Evaluation program. program. stored. Ensure they have had proper
approval from both the Supplier and FCA.
Samples and Appearance Manuals shall be maintained in a secure place to
prevent damage.

* CQI-8 Layered Process Audits (AIAG)

* FCA US LLC Customer-Specific Requirements
for ISO/TS-16949 cl. 4.12.2 - NAFTA
The Supplier shall conduct LPAs on all processes that produce production parts
or modules for FCA and any supporting processes. They shall have procedures
and work instructions for creating and conducting LPAs which adhere to the
AIAG's CQI-8 Layered Process Audits and include:
- meeting all ISO/TS-16949 Customer Specific Requirements for LPAs;
- creation and implementation of the Process Control Audit for each process
and supporting process;
- creation and implementation of the Error and Mistake Proofing Verification
Audit for each process and supporting process; * LPA Procedures and Work Systemic Review the Supplier's process for Layered Process Audits for conformance to requirements.
- detail of the roles and responsibilities for all levels of management; Instructions
- schedules and frequencies for all audits, and for each level of management
- records of results and reaction plans for nonconformances discovered during
any audit;
- updating the applicable audit for any nonconformances discovered at FCA
facilities;
- a requirement for regular top management reviews of audits and their
Layered Process results, with meeting minutes and open issues;
4B Audit - obtaining FCA approval prior to removing any item from the LPA

* CQI-8 Layered Process Audits (AIAG)

The Process Control Audit shall be done once per shift by a group leader or * FCA US LLC Customer-Specific Requirements
supervisor. Management audits shall be done weekly. Manufacturing areas * Process Control Audit Review an example of a Process Control Audit from Review the draft Process Control Audit form for the Witness at least one level of a Process for ISO/TS-16949 cl. 4.12.2 - NAFTA
shall be divided and auditors rotated so that all areas are included. The SQE procedures, instructions, Systemic another process. process. Control Audit.
checklist
shall witness at least one Process Control Audit during the Process Audit.

* CQI-8 Layered Process Audits (AIAG)

The Error and Mistake Proofing Verification Audit (see 3C) shall be completed * FCA US LLC Customer-Specific Requirements
once per shift or product change-over (whichever comes first) and whenever for ISO/TS-16949 cl. 4.12.2 - NAFTA
an unscheduled disruption occurs in the production line. The audit shall be * Error and Mistake Proofing Review an example of an Error and Mistake Proofing Review the draft Error and Mistake Proofing Witness the Error and Mistake Proofing
performed by qualified, trained personnel only. The SQE shall witness at least Verification Audit procedures, Systemic Verification Audit from another process. Verification Audit form for the process. Verification Audit prior to starting the PDR.
instructions, checklist
one Error and Mistake Proofing Verification Audit during the Process Audit,
performed prior to the PDR Stage 1.

* PF-SAFETY - NAFTA
* FCA norm 9.01120 - EMEA / LATAM
For parts with Safety/Report characteristics and/or subject to Homologation,
the Supplier shall have a process to identify, develop, and implement controls
on those characteristics (with results recorded and retained per FCA and Review list of expected Safety/Report characteristics,
regulatory requirements). Controls for safety/report characteristics shall be
identified on the Control Plan (and other quality documents), both on the step * Control Plan Technical Review Process Audit Process along with planned controls. Identify any monitored or
controlled by sub-tier suppliers, along with planned Update list and planned controls as needed.
Verify final list of Safety/Report
characteristics along with controls and data
in which the characteristic is generated and in a special annex that summarizes * Safety/Report records Evaluation controls. Review Supplier's record retention to ensure retention.
these controls. Controls performed by Tier 2 (or lower) Suppliers shall also be data is appropriately retained.
identified and maintain the same level of record management. The Supplier
shall meet all FCA requirements regarding Safety / Report characteristics, as
required (NAFTA: PF-SAFETY / EMEA / LATAM: FCA norm 9.01120).

Safety & Report

4C Characteristics * PF-SAFETY - NAFTA
Safety / Report characteristics shall have a primary check performed 100% by * FCA norm 9.01120 - EMEA / LATAM
Error/Mistake Proofing, as well as a secondary measurement audit performed
by Quality Auditors at specific sample sizes and frequencies and results * Control Plan Review list of expected Safety/Report characteristics, Verify all Safety/Report characteristics have
recorded on statistical charts. The acceptable checking method, sample size * Safety/Report audit data and Technical Review Process Audit Process along with planned controls. Ensure Error/Mistake Update list and planned controls as needed. efective Error/Mistake Proofing and
Evaluation Proofing is planned for each, as well as a defined
and frequency for establishing lot control within the Supplier’s facility shall be results secondary measurement audit. witness the secondary Quality Audit.
determined by the Supplier’s Control Plan and/or as directed by the FCA PPA
Team.

* PF-SAFETY - NAFTA
Nonconformances on Safety/Report characteristics shall be tracked, with * Supplier Notification of Shipment of
immediate containment of all product. Root Cause Analysis and Corrective Nonconforming Parts process - NAFTA
Action procedures shall be implemented immediately following containment. * Corrective Action procedures Systemic Review Nonconformance and Corrective Action procedures to ensure they meet requirements for Safety/Report characteristics. * FCA norm 9.01120 - EMEA / LATAM
The Supplier shall notify FCA (SQE, Plant Quality, etc.) immediately upon
detecting a potential issue on safety parts.

The Supplier shall have a documented First Piece Approval procedure and
instructions which verify proper set-up at each station and that parts made
meet applicable specifications. The procedure shall include:
- part approval by responsible personnel with specific approval instructions;
- analysis of all special characteristics and process parameters (for
conformance, drift, out-of-control conditions, etc.);
- 'OK to produce' given by responsible personnel after verification of Witness the Supplier performing the First
conformity to specifications of the first parts produced with a steady process; *and First Piece Approval procedure Process Audit Process Audit Process Review the Supplier's First Piece Approval process for Piece Approval process during the PDR.
4D First Piece Approval - requirements for First Piece Approval at the beginning of each shift,
instructions
Readiness Evaluation Evaluation conformance to requirements.
Update First Piece Approval process as required. Ensure the entire process is followed, even
* First Piece Approval results if the PDR is shorter than a normal
production run, and following any changes to the production process; production run or shift.
- retention of the First Piece Approval sample until the end of the production
run/shift and verification of the last piece produced at the end of the shift or
production run against the approved First Piece Approval sample;
- retention of the last piece produced at the end of the shift or production run
until verified against the First Piece sample of the next shift or production run;
- documented evidence of First Piece Approval results

Manufacturing facilities handling components that must be protected from

Electrostatic Discharge (ESD) shall have the following:
- ESD production areas separated from other areas of the facility, with climate
controls as necessary;
- ESD mats and/or floors;
- Heel and/or wrist straps (ESD certified shoes are acceptable);
- ESD testers for operators to verify heel and wrist straps, and/or shoe Review status of areas and equipment for handling Verify ESD facilities and equipment meet
efectiveness; requirements as listed. Ensure all parts run
- ESD testers with up-to-date operator instructions (including mandatory * ESD procedures and Technical Review Process Audit Process Review the Supplier's plan for any areas handling parts parts with ESD requirements. Ensure all necessary
equipment and facilities are available in time for parts during
the PDR have appropriate
testing of all personnel prior to entering the floor), included in the calibration instructions Evaluation with ESD requirements. protection and all operators are trained
for the first pilot build.
procedures, schedule, and Preventive Maintenance plan; properly.
- Clearly-identified ESD containers (e.g. bags, totes, etc.) for transporting ESD
sensitive product;
- ESD workbenches that are grounded with plugs for wrist straps, if applicable;
- ESD gloves and/or finger cots for handling of PCB's (e.g. rejects);
- ESD certification schedule mandating annual recertification, and record
retention, of equipment, tools, testers, containers, and personnel.

4E Special Processes
 * CQI-15 Special Process: Welding System
Assessment (AIAG)
4E Special Processes * FCA US LLC Customer-Specific Requirements
for ISO/TS-16949 cl. 4.12.3 - NAFTA
Suppliers with welding operations and processes shall meet all requirements in * FCA welding norms 9.5017#/## - EMEA /
CQI-15 “Special Process: Welding System Assessment”, including conducting LATAM
regular self-assessments and audits. In addition, they shall meet the following: * Applicable Standards, Certifications, and
- All welding technicians, operators, and inspectors shall be trained and licenses (per FCA, ANSI, AWS, UNI EN, etc.)
certified (to all applicable FCA, ANSI, AWS, UNI EN, etc. standards), with re-
training, re-qualification or re-certification as necessary;
- Include all welding cells in the Suppliers LPA Process Control Audit to ensure
conformance to requirements;
- The Supplier shall have objective evidence of a working weld conformance * Welding Assessment and Audit
system for a period of at least one year demonstrating control and corrective procedures and records
action on a daily basis; Verify parts with welding requirements
- All weld audits, assessments, and Control Plans shall include cut and etch as * Welding training plan, Technical Review Process Audit Process Review Supplier's plan for control of parts with welding Review status of plan and update as necessary. have the required controls and those
well as microscopic inspection; certifications, and records Evaluation requirements. controls are followed by the Supplier.
* LPA Process Control Audit
- The Control Plan cut and etch frequency for each weld shall be determined * Control Plan
by the PPA Team and be adequate to ensure that each lot of material has had
welds validated prior to shipment from the facility (i.e., four-wall containment).
This applies at the Supplier’s facility.
Suppliers with other special processes (e.g., heat treating, plating, painting,
etc.) shall have a process in place that includes the following:
- Operator training and certification;
- Inclusion of the process in the Supplier's LPA program;
- Conducting self-assessments to industry standards (as required);
- Process monitoring and data recording requirements.

* ISO/TS-16949 cl. 7.5.1.2 & 7.5.1.3

Work stations, inspection areas, etc. shall have clear operation, set-up,
changeover, First Piece Approval, Mistake Proofing, rework/repair, gage
operation, inspection, and packaging instructions according to the needs and
method of production. Instructions shall be visible and easily accessed by Verify work instructions are followed while
operators, inspectors, and other necessary personnel. During the planning and * Work Instructions: operation, Review and update work instructions as necessary. the Stage 1 PDR occurs. Ask operators,
development of these instructions, special attention shall be given to set-up, changeover, 1st Piece Ensure they are updated to the latest revision level. inspectors, etc. questions to ensure
Process Audit Review temporary or draft work instructions. Ensure
operations where inspections occur, and all special characteristics identified. Approval, Mistake Proofing, Tooling Kick-Of Readiness Evaluation visual techniques are used wherever possible. Ensure appropriate Supplier personnel approve final understanding and knowledge. Ensure
Instructions shall be clearly identified regarding their usage (e.g. classification, rework/repair, gage, inspection, work instructions prior to the Readiness Evaluation and work instructions are available to all
colors, pictures / sketches / drawings, etc.) to avoid any possible mistake. packaging release to the manufacturing floor. applicable personnel and they know where
Visual management techniques (e.g. displays, pictures, diagrams, etc.) shall be to locate.
used whenever possible. In cases where the facility workforce is multi-lingual,
visual-based work instructions shall be used in place of multiple, translated
copies.

* ISO/TS-16949 cl. 7.5.1.2 & 7.5.1.3

All operators, inspectors, set-up/changeover personnel, etc. shall be fully Verify work instructions are followed while
* Work Instructions: operation, Review and update work instructions as necessary. the Stage 1 PDR occurs. Ask operators,
5A Work Instructions trained and knowledgeable of the work instructions applicable to their area of
responsibility. They shall be able to apply all of the procedures and instructions set-up, changeover, 1st Piece Process Audit Review temporary or draft work instructions. Ensure Ensure they are updated to the latest revision level. inspectors, etc. questions to ensure
contained within. The instructions shall enable any adequately trained person Approval, Mistake Proofing, Tooling Kick-Of Readiness Evaluation visual techniques are used wherever possible. Ensure appropriate Supplier personnel approve final understanding and knowledge. Ensure
to perform the described operation or inspection. The SQE shall verify the rework/repair, gage, inspection, work instructions prior to the Readiness Evaluation and work instructions are available to all
efectiveness and adequacy of visual controls. packaging release to the manufacturing floor. applicable personnel and they know where
to locate.

* ISO/TS-16949 cl. 7.5.1.3

Set-up and changeover instructions shall include acceptable control limits for
process parameters (e.g. temperature, pressure, etc.) and verification of those
parameters during process set-up and/or re-start. They shall detail all required Verify set-up/changeover instructions are
steps, including of-line activities such as gage management. Control limits Review and update work instructions as necessary.
shall be determined using preliminary process analyses (e.g., assembly FMEA, Ensure they are updated to the latest revision level. followed during initial set-up and at least
DOE, knowledge of successive processes, knowledge of how the product is * Set-up, changeover instructions Tooling Kick-Of Process Audit Review temporary or draft work instructions. Ensure Ensure appropriate Supplier personnel approve final one changeover during the PDR (if
Readiness Evaluation visual techniques are used wherever possible. possible). Ensure the instructions are
used, engineering specifications and standards, etc.) and show evidence of work instructions prior to the Readiness Evaluation and accessible to the set-up/changeover
continual improvement. At a minimum, the Supplier shall analyze process release to the manufacturing floor. personnel and they know where to locate.
parameters that afect close tolerances, fit, function, finish, reliability,
durability, or that afect the successive/final process. NOTE: Ensure control
limits are not confused with tolerances.

* ISO/TS-16949 cl. 7.5.1.4

The Supplier shall have a Preventive / Programmed / Predictive Maintenance

plan which includes:
- identification of maintenance requirements for all tooling, equipment,
Error/Mistake Proofing, and gages used in the process, based on past history,
AQR, MPFMEA, PFMEA, etc.;
- identification of critical process equipment and assurance of dedicated
resources for its maintenance;
- schedules, responsibilities, and instructions for maintaining each item in the
plan; Verify Supplier is following the
- establishment of maintenance frequencies for each item, based upon maintenance activities as planned, and
historical data and lessons learned from similar processes, manufacturers Ensure tooling, gages, and equipment are added to the
specifications, etc.; * Preventive / Programmed / Review Supplier's general maintenance plan and maintenance plan as they become available (and prior documenting results. Ensure all tooling,
- addition of new tooling to the plan prior to production release; Predictive Maintenance plan Tooling Kick-Of Tool completion records on previous programs. to release to the Supplier's manufacturing floor). gages, and equipment have been included
* Maintenance records in the maintenance plan. Audit tooling,
- detail for the preservation and storage of tooling, equipment, and gages; Review initial maintenance plan for adequacy. gages, and equipment on other processes
- ensuring availability of replacement parts for critical or long-lead equipment to verify conformance to the plan.
that could result in plant shutdowns;
- recording, reporting, and tracking of maintenance data and goals (planned,
unplanned, etc.) and continual improvement activities;
- reviews and updates of the plan on a regular basis (i.e., evidence that it is a
living document);
- identification of maintenance activities performed by 3rd Parties (which must
be equal or superior to those of the Supplier)
The Supplier shall ensure that the planned maintenance activities are
performed per the established schedule.
5B Maintenance

Verify Supplier is following the

Maintenance records and related quality issues shall be analyzed to identify Review Supplier's general maintenance plan and Review any maintenance done during tool try-outs or maintenance activities and documenting
any weakness in the equipment and/or in the maintenance plan and optimize * Maintenance records Tool try-outs On-going records on previous programs. pilot builds. Ensure information is carried back as results. Audit tooling, gages, and
the process. lessons learned to improve the plan. equipment on other processes to verify
conformance to the plan.

The Supplier shall ensure that, as tooling and/or equipment approaches the
predetermined end of life cycle, appropriate actions are taken to ensure Systemic Review Supplier's process for "end-of-life" tooling for robustness and conformity to requirements.
conformity to requirements (e.g. increased inspections, enhanced detection
measures or methodologies).

There shall be a trained maintenance team, internal or external, available in

case of emergency during all production hours. All unplanned or special * Preventive Maintenance plan Verify Supplier has a trained maintenance team available for all shifts that the Supplier runs. Ensure emergency/unplanned maintenance activities are
maintenance activities, in any part of the Supplier's facility, shall be recorded * Maintenance records Systemic documented and tracked, with continuous improvement activities in place.
and tracked by the Supplier.
* ISO/TS-16949 cl. 7.5.1.5
The SQE shall verify the environment where dies/tooling, equipment, and Review storage facilities for tooling and
gages are stored when not in use. Items shall be clean, well-protected from Tool try-outs Process Audit Process N/A N/A gages to ensure items are properly
damage and environmental stresses, properly maintained, and easy to locate Evaluation
to ensure functionality through the life of the program. protected.

Work instructions and procedures shall be developed for reworking or

repairing nonconforming parts and require FCA approval. The instructions shall
define:
- the rework/repair process;
- criteria for determination of what parts shall undergo rework/repair (as Develop procedures and instructions for permanent
opposed to being scrapped); rework stations. Confirm the method that Witness the rework/repair process during
- the equipment and material to be used; * Rework/repair procedures and Tooling Kick-Of Process Audit Identify any proposed "permanent" rework or repair the PDR. Ensure the Supplier is following
reworked/repaired parts will be identified. Develop the all
- the methods of identification (all reworked/repaired product shall be clearly instructions Readiness Evaluation activities that will be used in the process. approved instructions and marking parts
and uniquely identified); training requirements and process for operators who in the agreed upon manner.
- controls used on the reworked/repaired product. Reworked and repaired will be performing the rework and repair.
product shall have controls and Error/Mistake Proofing equivalent, or superior
to, the primary production line.
The SQE shall verify the process and instructions are followed during the
Process Audit.
5C Rework & Repair

The Supplier shall have a procedure describing how temporary rework/repair

operations are created and controlled. This procedure shall include:
- identification of all personnel responsible for creating temporary
rework/repair operations, instructions, and controls.
- notification and approval from FCA Engineering and SQ (and Plant, as * Rework/repair procedures and Systemic Review the temporary rework/repair procedure for conformity to requirements.
required) prior to initiating temporary rework/repair via the appropriate instructions
process.
- requirements that rework/repair parts go through controls (including Error
and Mistake Proofing) equivalent or superior to the primary production line.

* ISO/TS-16949 cl. 6.2.2 - 6.2.2.4

The Supplier shall have a process for training and qualifying key personnel
(operators, supervisors, maintenance personnel, etc.) prior to performing Update training plan to include program-specific Verify training of operators used during the
production operations. Training requirements for each unique process / * Training plan requirements. Ensure personnel used for the Process Process Audit Readiness Evaluation and
operation shall be maintained. Key personnel training records shall be * Training records Systemic Review the Supplier's training plan and records.
maintained, including which personnel are certified to perform each process / * Skill matrix or records Audit Readiness Evaluation and Process Evaluation will Process Evaluation. Review records and
operation. The training plan shall have evidence of periodic reviews and be trained in time for those runs. ensure they have been updated.
updates of requirements, materials, and records.

* ISO/TS-16949 cl. 6.2.2 - 6.2.2.4

Operations or processes requiring special certification or licensing, and those
personnel who are certified/licensed to perform them, shall be identified. This
includes, but is not limited to:
5D Training - Operations or inspections using visual identification or appearance checks Review plan to train and certify required personnel for Verify personnel performing identified
(e.g., color/gloss checks); * List of operations and operators
- Operations or inspections using audial inspections (e.g., checks for BSR/NVH); requiring special certifications Technical Review Process Audit Process Identify any operations or portions of the process that the identified operations. Ensure personnel used for operations have been appropriately
- Inspections and checks on Safety/Report characteristics; * Skill matrix or records Evaluation will require special training or certification. the Process Audit Readiness Evaluation and Process trained and certified.
Evaluation will be trained in time for those runs.
- Rework/repair operations;
- Inspections or checks using specialized testing equipment or machinery (e.g.,
X-ray, magnetoscopes, etc.);
- Operations and processes sensitive to Electrostatic Discharge (ESD)

At the Process Audit, all key personnel needed to ensure that the Supplier’s * Personnel plan for support of Process Audit Process Audit Process Review plan for hiring of key personnel, if necessary. Review and update plan for hiring of key personnel, if Verify personnel needed to satisfy launch
process(es) can meet the required volume at launch shall be hired and fully requirements are available, and review
trained, and a plan shall be in place to support full production volume. production Readiness Evaluation Evaluation necessary. plan for supporting full production volume.

* ISO/TS-16949 cl. 6.4.2

The Supplier shall have a process to ensure workstation cleanliness (e.g. 5-S)
which is implemented daily (at a minimum). Evidence of completion shall be
maintained. Necessary items on or near workstations (e.g. tools, sub- Verify Supplier shows evidence of adhering
* 5-S (or equivalent) process Systemic Review Supplier's process for 5-S (or equivalent). N/A to their 5-S process and maintains records
Environment, component stock) shall be stored in designated areas. Small tools or similar of adherence.
5E Health, & Safety
items should be secured to the workstation. The SQE shall verify the process is
followed during the Process Audit.

EMEA: the Supplier shall have a Fire Prevention License (or equivalent). * Fire Prevention License Systemic Verify Fire Prevention License, if required.

* ISO/TS-16949 cl. 7.5.5.1

The Supplier shall have a procedure for First-in-First-out (FIFO) inventory
control for all material, including management of material with expiration * FIFO inventory control Review Supplier's FIFO procedures and plan to add applicable components and raw materials. Review the Witness and verify the Supplier's FIFO
dates. If the Supplier uses a computerized system, they shall have an efective procedures Systemic Supplier's backup plan for computerized systems, if applicable. process.
backup process to ensure FIFO in the event the primary system fails. The SQE
shall verify that FIFO procedures are followed during the Process Audit.

* ISO/TS-16949 cl. 7.5.5.1

The Supplier shall have a procedure for material handling and in-process
6A Material Handling material re-stock (e.g., Kan-Ban), including details on how material is tracked
and moved from one process to another. Material storage locations shall be
clearly identified and adequate for process requirements. Pallets, shelves, etc. Witness and verify the Supplier's material
shall be clean and well-maintained. Storage areas shall be sufficiently sized to * Material handling and re-stock Systemic Review the Supplier's plan for material handling and in-process re-stock. Ensure adequate space has been handling and re-stock procedures. Review
contain the material, located in a logical way with respect to process flow, and procedures allocated for the program's components and raw materials. Review the process layout for proper flow. storage locations for adequate protection,
adequate to contain and protect the product with easy access and safe organization, and space.
handling. Handling, transport and containing means (forklifts, pallets, etc.)
shall be efficient and operated under proper safety conditions. The SQE shall
verify that material handling procedures are followed during the Process Audit.

* ISO/TS-16949 cl, 7.5.3 & 7.5.3.1

The Supplier shall have a procedure for maintaining part traceability. Part
traceability shall be independent of inventory control processes (i.e., shall not
be FIFO-dependent). The Supplier shall demonstrate part traceability on all Prior to VP MRD
parts through all stages of production, from raw materials through the finished (Vehicle) Review plan for part traceability. Ensure it includes all Verify the part traceability by taking a
assembly and including sub-tier suppliers and shipping. NOTE: Some parts also * Traceability procedures Technical Review Prior to Gamma MRD stages, back through raw materials. Review and update plan as necessary. finished assembly and having the Supplier
require traceability codes / bar code labels to be present on the finished demonstrate on each component (see 7C).
assembly. These will be defined by the FCA engineering standards (typical (Powertrain)
parts include those covered by government regulations, Safety, Powertrain,
and those required by contract).

Prior to VP MRD * PF-SAFETY, PF-HOMOLOGATION, & PF-

For parts with Safety/Report characteristics or subject to homologation, it shall (Vehicle) Review list of Safety/Report characteristics and Review Supplier's plan for tracing results of inspections Verify Supplier's ability to trace results of EMISSIONS - NAFTA
be possible to trace back the results of inspections and tests per FCA Technical Review tests and inspections on Safety/Report * FCA norm 9.01102 - EMEA / LATAM
requirements and government regulations. Prior to Gamma MRD applicable requirements and regulations. or tests to the associated part. characteristics to the associated part.
(Powertrain)
* FIAT norm 07611
When required by FCA specifications, the finished part shall include the * FIAT norm 07170
Supplier's alphanumeric code, with proper modes (label, printing, molded in Prior to VP MRD Review Supplier's plan for part ID. Ensure Supplier
the part, etc.). Also when required by FCA specifications, parts delivered before Tooling Kick-Of (Vehicle) accounts for FCA ID requirements in the tool or process Review part ID against print and
the granting of Full Approval / PPAP or before Start of Production (whichever Prior to Gamma MRD Review FCA standards for part ID requirements. prior to kick-of, as applicable. specifications.
comes first) shall have a “Traceability Code” as defined by that standard. (Powertrain)

Parts inspected by Quality department audits shall be clearly identified and

traceable to the inspection process, auditor, gages, and personnel. Product
undergoing inspections shall be clearly segregated and identified as to: Verify Supplier follows the inspection
- product waiting to be inspected; * Quality inspection procedures Review Supplier's Quality inspection procedures and instructions. Ensure they allow for traceability back to the procedures and instructions. Verify product
- product inspected and accepted with the acceptance date (year, month, day, and instructions Systemic inspector and tools used. Ensure product is identified as indicated in the requirements. undergoing or waiting for inspection is
numeric sequence);
- product waiting for a disposition; appropriately identified.
- nonconforming product;
- product to be scrapped (i.e., non-reworkable or repairable)

All materials used in the process shall be clearly identified and diferentiated
(set-up parts, rework/repair, scrap, Work in Process (WIP), sub-components,
etc.). Identification labels shall be clearly visible on each container, with lot
number, date, quantity, and part number, at a minimum. WIP shall also be Prior to VP MRD Verify materials used in the process are
identified with operator/supervisor, operation number, number of pieces (Vehicle) Review Supplier's plan for identification of materials at Review and update the plan, as necessary. Review appropriately segregated and
entering/exiting the operation, number of pieces reworked/ repaired, number * Material handling procedures After source selection Prior to Gamma MRD all stages of production. internal and external labeling prior to the first pilot
builds. identified/labeled. Ensure identification
Traceability & Part of pieces scrapped, operation number and shift. Identification shall be clear, (Powertrain) meets minimum requirements as listed.
6B Identification even after the partial use of the lot. Parts used for set-up or inspection
purposes shall be clearly identified and stored in a way that prevents
accidental shipment.

Parts shall be identified per FCA requirements, in a manner consistent with the Prior to VP MRD * PS-4480 - NAFTA
risk of the part/process. Product identification/marking shall be written, in (Vehicle) Review Supplier's plan for part ID. Ensure Supplier * FCA norm 9.01106/02 - EMEA / LATAM
Design completion Review FCA standards for part ID requirements. accounts for FCA ID requirements in the tool or process Review part ID against print and
case of assemblies, on all components of the assembly, if they are available Prior to Gamma MRD prior to kick-of, as applicable. specifications.
loose on the spare parts market. (Powertrain)

Sorted, reworked or repaired material shall be traceable back to the sort,

rework or repair process. In addition, parts undergoing rework/repair shall
adhere to the following:
- when a sub-component is replaced which has Safety/Report characteristics,
the lot from which the replacement sub-component came shall be identified
and linked with the final assembly on which it was used; Process Audit Process Review plan for traceability of reworked and repaired Verify rework/repair parts are traceable
- when a sub-component is removed from an assembly which has been Tooling Kick-Of Evaluation parts. Review and update plan as necessary. per the requirements, as applicable.
returned from an FCA facility and re-used in another assembly, the lot code of
all sub-components with Safety/Report characteristics shall be identified and
traceable to the new assembly in which the component was used;
- traceability maintained if a part returned from an FCA assembly plant is to be
re-sent without rework or repair performed (e.g. parts sorted as “good” from a
returned, quarantined lot).

There shall be a link between packaging labels (for both internal and external
containers) and the product, lot, packing list, quantity, revision level, sub-
components and other relevant information.
The Supplier shall also send to FCA EMEA plants (including Powertrain and IRF
Poles) AVIEXP/ASN (advance shipment notice) for each physical shipment
(telematic and physical shipment at the same time) according to CGA and Prior to VP MRD Review and update the plan, as necessary. Review
following FCA procedure 71092 rules. After source selection (Vehicle) Review intended packaging labels for internal and internal and external labeling prior to the first pilot Verify labels meet the requirements listed.
Not sending (or sending partial) Aviexp/ASN will result in SQP penalization as Prior to Gamma MRD external containers. builds.
written into FCA procedure 08018. AVIEXP/ASN can be sent via EDI connection (Powertrain)
or Web portal (all information can be found on the FCA Logistic Portal at
https://fiat4suppliers.fiat.com/LOGISTICS)
NOTE: AVIEXP transmission is mandatory. AVIEXP provides FCA plant detailed
information about actual deliveries and facilitates material receiving process.

There shall be a link between packaging labels (for both internal and external containers) and the product, lot, packing list, quantity, revision level,

The Supplier shall specify all containers used in the process, both internally Verify Supplier is following packaging
and externally, in the packaging or work instructions. Specific information shall
include container dimensions, material, pieces per container, weight of Prior to VP MRD instructions. Review shipping/receiving and
container (full and empty), containers per pallet, maximum stacking height, * Packaging instructions Technical Review (Vehicle) Review initial packaging plan. Determine responsibility Review and update packaging plan, as necessary.
Complete packaging instructions. Ensure packaging
storage areas / warehouses and verify
packaged parts are adequately protected.
etc. All packaging and labeling for product being shipped to FCA shall conform Prior to Gamma MRD for packaging containers /racks (FCA or Supplier). availability for pilot builds. Verify that internal containers (i.e., for
to all FCA requirements. During receiving, shipping, and storage operations, (Powertrain) Work-in-Process) are adequate and prevent
environmental conditions shall be such as to protect the integrity of the part
and packaging. damage to parts stored within.

For all Supplier-designed packaging (internal and external):

- the Supplier shall be responsible for designing, manufacturing, testing, and
documenting expendable packaging test data (simulated or actual); Prior to VP MRD Review initial packaging plan. Determine responsibility Verify testing for Supplier-designed parts
- packaging shall be designed to ensure, even in the case of repackaging, the (Vehicle) for packaging containers /racks (FCA or Supplier). For Review packaging test plan and timing; update as was completed successfully and all open
integrity of the single component until its use in the production cycle; Technical Review Prior to Gamma MRD Supplier-designed packaging, review test plan and necessary. Ensure completion prior to required pilot issues have been closed (if any). Ensure
- testing (e.g. shaker table, rail or over the road etc.) shall be performed based build. adequate quantities of packaging are
upon the mode of transit; (Powertrain) timing. available for plant part releases.
- simulation tests and/or shipping tests shall be conducted prior to VP
(Verification of Process) and be documented.

The Supplier shall have a procedure for the management of returnable

6C Packaging containers and dunnage. This procedure shall include:
- access and training for the appropriate FCA container management system;
- mandatory data entry into the appropriate FCA system;
- inventory control procedures to track containers on-hand and in-transit from
FCA;
- procedures for mandatory transmittal of container and/or part number * Returnable container Review returnable container management plan and verify conformance to requirements. Verify that back-up expendable packaging meets the same
information during computer submissions from the Supplier; Systemic
- procedures for identification and disposition of contaminated or damaged management procedure requirements as the primary returnable packaging.
containers received;
- an expendable back-up plan in the event of a shortage of returnable
containers. Back-up expendable packaging shall maintain the same dimensions
as the returnable container (and contain the same number of pieces).
NOTE: The Supplier is not responsible for the approval of FCA-designed and
mandated packaging.

The Supplier shall not use FCA-owned and provided containers for internal N/A Emphasize requirement to Supplier. Emphasize requirement to Supplier. Verify FCA-owned packaging is not being
handling or WIP. used improperly.

Bar code labels shall:

- be generated one at a time and only following successful completion of the
Prior to VP MRD
previous operation (e.g. after passing an end-of-line tester, after correct (Vehicle) Review labeling requirements and plan for meeting Ensure Supplier has appropriate bar code labeling in Verify Supplier is meeting all bar code
scanning of the correct material, etc.) when done at the final operation; Technical Review Prior to Gamma MRD those requirements. place prior to the first pilot build. labeling requirements and has appropriate
- have logic in place to prevent printing of duplicate bar code labels; error and mistake proofing in place.
- have logic or error proofing to ensure labels match the part for scanning (Powertrain)
purposes

* Module Source Package Boilerplate - NAFTA

For parts that follow Sequenced Part Delivery (SPD), the Supplier shall: * FIAT norm 71029 - EMEA / LATAM
- maintain SPD sequence throughout the entire process (including
repair/rework);
- have backup systems to ensure receipt of the broadcast / EDI;
Witness Supplier build to the broadcast.
- use barcodes and/or pick lights with break beams to ensure correct part Prior to VP MRD Review and update plan, as necessary. Ensure all Ensure all requirements for SPD are being
Sequenced Part selection and assembly; (Vehicle) Determine if the Supplier will be required to perform
6D Delivery - use vision systems or color sensing to ensure correct components and color
Technical Review
Prior to Gamma MRD SPD ("just-in-time"). Review initial plan if yes.
requirements are in place prior to the required pilot met and Supplier has adequate error-
match (as applicable); (Powertrain) build. proofing to prevent incorrect part
- ensure components with Safety or Report characteristics are traceable to the selection.
VIN sequence;
- employ additional tracking to maintain sequence and delivery in cases of
rebroadcast due to non-repairable conditions
 The matrix score evaluation in function of CAPMAN output
The matrix score evaluation in function of CAPMAN output 0% has to be evaluated 1
0% has to be evaluated 1 1% - 59% have to be evaluated 2
1% - 59% have to be evaluated 2 60% - 89% have to be evaluated 3
60% - 89% have to be evaluated 3 90% - 94% or any percentage but with and mean age < 7gg have to be evaluated 4
90% - 94% or any percentage but with and mean age < 7gg have to be 95% - 100% have to be evaluated 5
6E CAPMAN evaluated 4
Systemic Verify Supplier is using CAPMAN to upload required logistics data.
Action plan to be considered: from 1 to 100 Part numbers: two weeks; more than 100 PN: Three weeks
95% - 100% have to be evaluated 5 NOTE: The CAPMAN score doesn't contribute to the final PA score
Action plan to be considered: from 1 to 100 Part numbers: two weeks; more
than 100 PN: Three weeks
NOTE: The CAPMAN score doesn't contribute to the final PA score

The Stage 1 Production Demonstration Run (PDR) shall be completed during

the Process Audit. The Process Audit and PDR shall be run on finished
production tools using definitive production processes (i.e., "homeline"). The Verify the Supplier has the latest information about the Readiness Evaluation: run agreed upon
Supplier shall meet the required line speed based on the Contract Capacity, requested volumes, the sequence of the launching number of parts. If parts are to be used for
and shall run a minimum of 300 parts or 2 hours of production per part version, the ramp-up curve, and the product mix. Update volume, capacity, and launch ramp-up testing, ensure required line speed is met
Capacity, Volume, number, whichever is more. First Time Capability (FTC) for the final process Review the quoted Contract Capacity with the Supplier information as necessary. Verify required line speed for (and parts meet all other requirements;
* Contract 4 weeks prior to
7A & PDR
shall be 90% or greater, and Line Utilization 90% or less.
* PDR Tool Kit
Technical Review
launch
and determine the required line speed for the PDR. Identify potential constraints and bottlenecks, see 9A).
NOTE 1: Deviating less than the 300 parts or 2 hours of production Readiness Evaluation and PDR. Review the shift pattern with appropriate action plans to minimize their efect. Process Evaluation: run the Stage 1 PDR
requirement requires the approval of the FCA Engineer, SQE, and SQ Manager. to ensure that it supports production and allows Review launch ramp-up plan. and confirm dates and requirements for
Deviating from the FTC or Line Utilization requirements also requires the enough time for PM activities. Determine the timing the Stage 2 PDR. Review launch ramp-up
approval of the FCA Engineer, SQE, and SQ Manager. and run requirements for the Stage 2 PDR. plan.
NOTE 2: For the Readiness Evaluation trial run, the Supplier and FCA Engineer
and SQE shall agree upon the number of parts to run.

* AIAG Statistical Process Control manual (2nd

The Supplier shall demonstrate process performance / capability for all
identified special characteristics. All parts used in this study shall come from
the PDR. Performance/capability shall meet FCA requirements as defined in
the PDR and in the "Performance Requirements" tab and results recorded on
or attached to the PDR Toolkit forms. Special characteristics (see 1D) require
variable data; any using attribute data shall be agreed to by the FCA team and
100% of the parts shall be acceptable.
NOTE 1: For new programs, process performance should be used (P P/PPK). For * PDR Tool Kit
current production processes, process capability should be used (C P/CPK).
Performance / capability should be calculated individually for each assembly
line, tool, and tool cavity.
NOTE 2: Process capability on special characteristics is monitored over time to
guarantee ongoing stability. This should be done using adequate SPC
techniques and/or recalculations at fixed intervals. Reference the applicable
FCA standards or manuals.
NOTE 3: All characteristics on the part, regardless of classification, shall meet
FCA requirements.
Update characteristics that will require measurement
as necessary. Review preliminary data for prototypes
and early pilot builds. If the component doesn't meet
Review and agree upon characteristics that will be
the quality requirements for the program milestones,
required to be measured at the Process Audit / PDR.
* Performance / capability data & Process Audit Process Audit Process Ensure all special and critical characteristics are review the level of risk for the issuing of an interim
results Readiness Evaluation Evaluation included. Determine number of parts that will be approval for the use of the part. Ensure adequate risk
mitigation activities are in place when an interim
measured. approval is required. Review the status of any existing
interim approvals (and corresponding engineering
changes).
Edition) - NAFTA
* FCA norm 9.01102 - EMEA / LATAM
* Global Characteristic Commonization XXXX
Review performance / capability study * FCA Process Planning & Audit Manual,
results. Ensure all agreed-upon Appendix B
characteristics on the correct number of * PDR Toolkit "Performance-Capability Reqs."
parts have been measured. Verify parts
meet the performance / capability
requirements based on the criticality of the
characteristic. If the component doesn't
meet the quality requirements for the
program milestones, review the level of
risk for the issuing of an interim approval
for the use of the part. Ensure adequate
risk mitigation activities are in place when
an interim approval is required. Review the
status of any existing interim approvals
(and corresponding engineering changes).

Process * AIAG Statistical Process Control manual (2nd

7B Performance &
Capability If the process performance / capability is less than the established
requirement, then 100% verification of the product shall be performed.
Permanent corrective actions shall be implemented before the Process Audit
can be approved. Corrective actions shall include:
- periodic reviews of data and control limits;
- review and updates/increases of sample sizes and frequencies as necessary; Assessment
- recording/documentation of actions taken;
- verification of the efectiveness of actions taken.
If the process is determined to be unable to maintain process
performance/capability, Error or Mistake Proofing shall be implemented for
100% mechanical verification and can be considered the Permanent Corrective
Action at the FCA team's discretion.
Edition) - NAFTA
* FCA norm 9.01102 - EMEA / LATAM
* Global Characteristic Commonization XXXX
* FCA Process Planning & Audit Manual,
Appendix B
* Manufacturing Feasibility Review the Manufacturing Feasibility Assessment. * PDR Toolkit "Performance-Capability Reqs."
Process Audit Process Identify any potential concerns where performance / Review preliminary data for prototypes and early pilot Review performance / capability study
results. Implement corrective actions for to
* Performance / capability data & Technical Review builds. Implement corrective actions to address any
results Evaluation capability may not be able to be met. Review items that do not meet the requirements. address any items that do not meet the
* Corrective action records corrective action plans for addressing this issue. requirements.

* AIAG Statistical Process Control manual (2nd

Machine capability (CM/CMK) shall be used for "Shoot-and-ship" parts or when Edition) - NAFTA
* FCA norm 9.01102 - EMEA / LATAM
analyzing a characteristic unique to a particular machine. Machine capability Review machine capability data on special Review machine capability data on special * Global Characteristic Commonization XXXX
* PDR Tool Kit Process Audit Process Identify characteristics to be measured for machine characteristics before releasing tooling from the characteristics before releasing tooling
shall be re-calculated when there are any modifications to the product or * Performance / capability data & Technical Review * FCA Process Planning & Audit Manual,
process, significant maintenance is done on the machine, or when the results Evaluation capability. toolmaker to the Supplier. Re-evaluate after any tool from the toolmaker to the Supplier. Re- Appendix B
machine is moved. Machine capability shall be calculated on all FCA-owned changes or moves. evaluate after any tool changes or moves. * PDR Toolkit "Performance-Capability Reqs."
tooling.

The SQE shall perform an audit or inspection on sub-components and finished

parts during the course of the Process Audit. The SQE shall:
- determine the number of parts checked at each area / operation, based upon
risk level and significance of the characteristic (15 is recommended);
- verify that inspection personnel are adequately trained in the inspection * Control Plan Process Audit Process Evaluation N/A N/A
process; * Inspection / gage instructions
- verify inspection methods are performed in a way that is consistent and
adequate with the inspection requirements;
- evaluate the adequacy of the measurement method;
- ensure the selected parts are conforming.

In the Incoming or Receiving Material Area select one or more sub-

components from previously accepted/approved lots and witness the Supplier * Control Plan
inspect them per the Control Plan. The SQE shall also verify that the raw * Inspection / gage instructions Process Audit Process Evaluation N/A N/A
material being used meets FCA requirements.
Select the sub-components, in-process
operations, and final assemblies to be
In the Manufacturing Area, the SQE shall select in-process or finished parts checked, plus the quantity. Select one part
7C SQE Audit from a minimum of three diferent machines/processes and diferent
* Control Plan for traceability / lot control demonstration.
operators and witness the execution of the inspections (per the Supplier's Process Audit Process Evaluation N/A N/A Perform the SQE Audit per the
Control Plan), checking the consistency of the results with previously recorded * Inspection / gage instructions requirements.
inspections, and comparing them to the specifications.

In the Shipping Area the SQE shall select finished samples from previously * Control Plan
* Inspection / gage instructions
accepted/approved lots that are ready to be shipped and witness the Supplier * FPSC plan or Strengthened Process Audit Process Evaluation N/A N/A
inspect them per the Control Plan and Safe-Launch activities. Control Plan

Nonconformances found while performing the SQE Audit shall have root cause
analyses performed, and corrective actions approved (by the SQE and Supplier * Corrective Actions Process Audit Process Evaluation N/A N/A
Management) and implemented prior to Process Audit approval.

The SQE shall verify the Supplier's ability to maintain traceability on the
finished product. The Supplier shall demonstrate, on one finished assembly,
the traceability back to the raw materials or applicable sub-tier supplier on one Process Audit Process Evaluation N/A N/A
or more sub-components selected by the SQE.
* Production Part Approval Process manual (4th
Sub-components not considered low risk shall have a Process Audit (or Verify all sub-components have been Edition)
equivalent) and Production Demonstration Run led by the Supplier and * PA/PDR results for M/H risk approved for use. Review PPAP packages of
followed with a Level 3 PPAP submission (or equivalent approval) to the sub-components After source selection Process Audit selected sub-components for conformance
Supplier (see 2E). Sub-components considered low risk shall be submitted with *submissions
Sub-component PPAP Readiness Evaluation See 2E See 2E with requirements. Verify there are no
& samples capacity issues with any sub-components
a Level 1 PPAP (or equivalent) to the Supplier, at a minimum. or raw materials.

If sub-component approval is granted via deviation, it shall be temporary and

shall indicate the quantity and/or the valid time period. Deviation on sub- Review status of sub-components prior to VP build.
components must be approved by the FCA Engineer first, then approved by Determine if any require deviations or interim Ensure no sub-components being used are
the applicable Supplier department(s). NOTE: Violation of this requirement * Sub-component Deviations Systemic N/A approvals to be used (and if therefore, the final under a deviation. If so, make the
requires immediate placement of the Supplier on 3CPR (NAFTA) or CSL determination if the PA/PDR will need to
(EMEA/LATAM) Level 2. Process Audit approval will not be given if any sub- assembly also requires a deviation). Implement risk be run again.
component is under a deviation and/or not approved (except for Directed or mitigation plans as required.
Sub-Component Consigned components; see below).
7D Approval

Quality planning, Process Audit, and PDR activities on Directed Tier 2

components shall be led by FCA, supported, as necessary, by the Tier 1
Supplier. The Tier 1 Supplier shall be responsible for the on-going quality of
the Tier 2 components following PPAP. The Directed Tier 2 Supplier shall Review the status of Directed and
provide pilot, launch, and ongoing production support to the Tier 1 Supplier in Identify if any sub-components are Directed or Review the status of Directed and Consigned Consigned components and plan for the
the same manner they would FCA. NOTE (NAFTA): Process Audit Approval for Systemic Consigned. Review the timing plan for those parts, if components and plan for the pilot builds. Review risk pilot builds. Review risk mitigation plans, as
modules containing Directed or Consigned sub-components, shall not be known. mitigation plans, as applicable.
withheld due to a lack of PPAP on the FCA-led Directed / Consigned sub- applicable.
component. A “Directed” component is classified as a component given the
“VT” lineup code in CQMS. A “Consigned” component is classified as a
component given the “VX” lineup code in CQMS.

* ISO/TS-16949, cl. 7.5.2

* FCA US LLC Customer Specific Requirements
The Supplier shall have a process that ensures annual validation / for ISO/TS-16949, cl. 4.13 - NAFTA
recertification as required by FCA. The process shall include: * FCA norm 07740 - EMEA / LATAM
- full part layout(s) to dimensional requirements;
Annual Validation - all testing as detailed in the DVP&R or AQF; * Annual Validation process
7E & Periodic - ensuring annual validation / recertification is done on-time and that conflicts * DVP&R (NAFTA) Systemic Review plan for concurrence to requirements. Audit one or more parts on past programs to verify that annual validation / recertification is performed.
Recertification are avoided in the event of multiple parts being due at the same time; * AQF (EMEA / LATAM)
- obtaining a written waiver from the FCA representative if annual validation is
not required. This waiver is required for each year in which validation is not
performed.

* ISO/TS-16949 cl. 8.5.2-8.5.2.4

The Supplier shall have a Corrective Action procedure. This procedure shall
include:
- training and use of appropriate Problem Solving and Root Cause Analysis
tools (e.g. 3 Legged 5 Why, Critical Thinking, LUA/LUR, etc.);
- use of the appropriate FCA tool/system for documentation (GIMS, eCIMS,
SQP, 8-step/8-D);
- identification and containment of nonconformities including inspection of
parts back to the last 'in-control' or acceptable point (at a minimum);
- development of interim and long-term corrective actions with clear target
dates and escalation procedures when target dates are not met;
- verification of corrective action efectiveness; Review Supplier's Corrective Action procedure and tools used for conformance to requirements. Review and approve corrective actions as they become
- ensuring updates of applicable quality documents (PFMEA, Control Plan, * Corrective Action procedures Systemic necessary.
Work Instructions, etc.);
- ensuring the communication of lessons learned, “best practices,” and known
systemic weaknesses throughout the facility (and all other facilities within the
company);
- assignment of the corrective action to an individual, with target and actual
dates;
- tracking the progress of implementation of corrective actions;
- ensuring communication of quality and manufacturing issues across shifts,
departments, and personnel;
Non-Conformance - management involvement in the reporting of quality issues and tracking and
8A Management & approval of corrective actions.
Corrective Actions

* ISO/TS-16949 cl. 8.3 - 8.3.4

The Supplier shall have procedures for handling of nonconforming product,

including receiving, internally produced, and returned material from the FCA
Plant. These procedures shall include:
- defect tracking methods at all inspection stations/areas (e.g., tally or scrap
sheets);
- proper identification of returned, rejected, or scrapped material; Review Nonconforming hold area and
- proper storage of quarantined material in a locked or controlled area, with * Nonconforming handling ensure it meets requirements. Verify
quarantined material identified with part number, number of pieces, date procedures Systemic Review Nonconformance Handling procedure for conformance to requirements. Supplier follows when nonconforming
quarantined, reason for quarantine, and expected disposition date; material is discovered at FCA, internally,
- maximum amount of time allowed for disposition of quarantined product; and shipped in from sub-tier suppliers.
- coordination with the FCA Plant or sub-tier supplier to purge suspect material
and replacement of that material;
- immediate implementation of Corrective Action procedures;
- notification to the FCA Plant and SQE immediately upon identifying shipped
suspect material.

* ISO/TS-16949 cl. 7.4.1.2 & 7.4.1.3

* FCA US LLC Customer Specific Requirements
The Supplier shall have a list of approved sub-tier suppliers for each sub- for ISO/TS-16949 cl. 4.7 - 4.7.4 - NAFTA
component, raw material, commodity, technology, or purchased service.
Performance (quality, delivery, etc.) of each sub-tier supplier used shall be Verify Supplier's process for monitoring sub-tier
monitored and tracked on a regular basis (minimum monthly). Sub-tier suppliers and raw material suppliers. Review the list of
* Approved sub-tier supplier lists sub-tier/raw material suppliers and toolmakers to be Review sub-tier supplier list and
suppliers with unacceptable performance shall not receive new business from Systemic used on the program and verify that they have Review sub-tier supplier list and performance. performance. Verify continued
the Supplier until corrective actions have been implemented and verified, and * Sub-tier supplier performance acceptable performance, and that they are on any conformance.
performance has improved. All toolmakers used by the Supplier shall be ISO-
9001 certified, at minimum. NOTE: If the material, commodity, etc. has an FCA EASLs that apply. Ensure toolmakers are ISO-9001
Engineering Approved Supplier List (EASL), the Supplier shall only use sub-tier certified.
suppliers from that list.

* ISO/TS-16949 cl. 7.4.1.2 & 7.4.1.3

Sub-Tier The Supplier shall have individuals with the assigned responsibility of * FCA US LLC Customer Specific Requirements
8B Management managing the quality of sub-tier suppliers (e.g., a Supplier Quality for ISO/TS-16949 cl. 4.7 - 4.7.4 - NAFTA
organization). This includes performing quality planning and process audits for Systemic Review Supplier's organization for monitoring sub-tier performance and acceptability.
new programs and management of current quality performance and issues.

* ISO/TS-16949 cl. 7.4.1.2 & 7.4.1.3

* FCA US LLC Customer Specific Requirements
The Supplier shall ensure all FCA quality requirements (e.g., AQR, quality for ISO/TS-16949 cl. 4.7 - 4.7.4 - NAFTA
planning, Process Audit, Forever Requirements, etc.) are communicated
throughout the Supply Chain. The Supplier shall request approval from FCA for
all process changes using the appropriate system or process (e.g., the Forever Review Supplier's process for communicating FCA requirements throughout the Supply Chain. Verify that they have ensured that all levels of the Supply
Requirements system) prior to implementing a change. In addition, the Systemic Chain understand and adhere to the FCA Forever Requirements process.
Supplier shall ensure these requirements are communicated down throughout
the Supply Chain. The Tier 1 Supplier is ultimately responsible for all changes
initiated by their sub-tier suppliers and the Supply Chain.

Review the Master PFMEA for this part/commodity

The Supplier shall have a process for documenting lessons learned and
ensuring they are carried forward to future programs and all sister facilities
8C Lessons Learned within the same company. This includes obtaining and reviewing the FCA
Master PFMEA (if available) at the beginning of the program.
* Lessons Learned process
* Master PFMEA (if applicable)
and ensure all potential failure modes have been
accounted for in the Supplier's PFMEA and process.
Review quality spills and lessons learned from previous
and similar products / processes. Verify that issues
resulting in past quality spills, yardholds, or Field Update Master PFMEA as required and ensure Verify all items in the Master PFMEA have
Actions are adequately error-proofed or completely
Systemic designed out of the part in the new process. Review associated Supplier DFMEA and PFMEA is updated, as been accounted for in the Supplier's
the risk that the current part configuration will result in required. PFMEA, Error and Mistake Proofing, etc.
a high evaluation on internal indicators for quality
perception audits (e.g., CPA, TOC, ICP). Ensure that
issues resulting in high scores on previous programs for
similar products have been evaluated and corrected in
the design, DFMEA, and PFMEA, as appropriate.

* ISO/TS-16949 cl. 8.2.1 & 8.2.1.1

* FCA US LLC Customer Specific Requirements
The Supplier shall have a process for warranty analysis and prevention which for ISO/TS-16949 cl. 4.10 - 4.10.5 - NAFTA
includes review/analysis of samples from the field, root cause analysis, and
implementation of corrective actions. This process shall include accessing and
reviewing information in the applicable FCA warranty systems on a regular
8D Warranty basis. Tier 2 and lower suppliers shall be included in the reviews and corrective * Warranty process Systemic Review the Supplier's warranty process for conformance to the guidelines.
actions, as applicable. The Supplier shall also meet any additional FCA-specific
warranty requirements. NAFTA Suppliers shall meet the requirements in the
AIAG's CQI-14 Consumer Centric Warranty.

* NAFTA Suppliers send ISO/TS-16949 and ISO

14001 certifications to: ts16949@fcagroup.com
* EMEA/LATAM Suppliers upload ISO/TS-16949
The Supplier shall be certified to ISO/TS-16949 and have their certificate and ISO 14001 certifications to the SQP system
* ISO/TS-16949 Certification Systemic Verify certification has been sent to or uploaded to the applicable FCA system. available through eSupplierConnect.com
Quality uploaded into the applicable FCA system(s)
8E Certifications &
Record Retention
The Supplier shall have a process for retention of quality documents, records, * ISO/TS-16949 cl. 4.2.3 & 4.2.4
inspection results, etc. that follows ISO/TS-16946 4.2.3 and 4.2.4, FCA, and * Records Retention process Systemic Review records retention process.
regulatory requirements.
* ISO/IEC 17025

Review the Supplier's testing facilities and equipment.

Has the Self-Qualification test plan been shared? If not, are there clear
corrective actions or risk mitigation plans to complete the test plan? Have the
reliability targets been validated virtually or physically (on bench) with the
characteristics defined and results reviewed by Engineering? NOTE: If a 3rd
Party lab will be used for performing testing, layouts, etc. it shall be certified to
ISO/IEC 17025. NOTE 2: Parts for Self-Qualification testing shall be OTOP (Of-
Tool Of-Process).
Review any appropriate certifications. If the Supplier is
not able to perform the tests and/or dimensional
layouts expected of them, review their plan to use 3rd
party ISO/IEC 17025 certified labs. Review the
Supplier's Self-Qualification plan. Is the forecasted
Process Audit Process closing date of Self Qualification Tests consistent with
* AQF plan After source selection Evaluation the timing of Project? Does the Supplier's testing plan
take into account the reliability requirements and
tests? Is it updated according to the development level
of the Project? Has the plan been shared with FCA
Engineering? Review the status of the testing
(completed tests, on-going tests, approval status, etc.).
For on-going tests, what is the risk of a negative result?
Review the Supplier's Self-Qualification plan. Is the
forecasted closing date of Self Qualification Tests
consistent with the timing of Project? Has the plan
been shared with FCA Engineering? Review the status Verify the status of the Self-Qualification
of the testing (completed tests, on-going tests, and Integrative Test samples.
approval status, reliability verification - virtual or
physical, etc.). For on-going tests, what is the risk of a
negative result?

Planning of Self-
9A Qualification Tests
Testing failures shall have root cause analysis, implemented corrective actions, and be fully retested; it is unacceptable to simply replace the failed
Have the reliability targets been identified in the product card? Have they been Process Audit Process Review reliability test plan and ensure all requirements are met.
compared to historical data on similar parts / processes? If yes, has the root * Reliability Plan After source selection
cause of any gaps been included in the DFMEA and PFMEA? Evaluation

P
V
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e
s
t
s
a
m
p
l
e
s
Review the forecasted delivery date of Integrative Tests
s
Have the samples for Integrative Testing been delivered? If not, has a delivery * Integrative Test Plan After source selection Process Audit Process samples to ensure consistency with the timing of Review and update timing plan for Integrative Tests
Project (taking into account also the lead time of FCA and Verify status of Integrative Test samples. h
date been planned? * Reliability Plan Evaluation reliability. a
Labs). Evaluate the risk of a negative result of
Integrative Tests. l
l
:
-
Suppliers shall have a Craftsmanship Quality Procedure for all components with appearance requirements. This procedure shall include team mem
c
Planning of o
9B Integrative Tests m
e

f
r
o
m

a
P
r
o Supplier shall deliver parts to the FCA Assembly Plant per PQP requirements (typically data on 5 parts, plus 2 fully marked-up samples at eac
The
c
e
Review the plan for obtaining Benestare s
Review the plan for obtaining Benestare approval. Review the plan for obtaining Benestare approval. approval. Ensure the forecasted delivery s
Ensure the forecasted delivery date of samples is Ensure the forecasted delivery date of samples is date of samples is consistent with program
Planning of consistent with program timing (taking into account consistent with program timing (taking into account timing (taking into account the lead time of
A
Have the samples for Matchability and Benestare been delivered? If not, has a the lead time of the Plant Lab / Metrology Center). the lead time of the Plant Lab / Metrology Center). the Plant Lab / Metrology Center). Review
9C Matchability / delivery date been planned?
0 VP Build DaP
Review the plan for matchability submission. Is the Review the plan for matchability submission. Is the the plan for matchability submission. Is the u
Benestare availability of samples consistent with the timing of the availability of samples consistent with the timing of the availability of samples consistent with the d
Project? Ensure that there is a timing "safety factor" in Project? Ensure that there is a timing "safety factor" in timing of the Project? Ensure that there is i
the event of reoccurrence of the tests due to failures. the event of reoccurrence of the tests due to failures. a timing "safety factor" in the event of t
reoccurrence of the tests due to failures.
R
e
* www.mdssystem.com a
* Fiat Cap. 9.01102 – Fiat Cap. 9.01108 - EMEA / d
The Supplier shall have a process for Material/Substance Composition LATAM i
reporting via the International Materials Data System (IMDS), and be registered n
at www.mdsystem.com. This process shall include: e
- reference to all FCA requirements for IMDS; s
- communication with sub-tier suppliers regarding sub-component IMDS data,
and retention of sub-tier documentation; Review the Supplier's plan for management of International Materials Data System (IMDS) submission. Ensure they are registered to www.mdssystem.com, s
- communication to FCA of any changes/updates to IMDS data and retention of * IMDS Process Systemic and that they keep copies and records of their submissions. Verify they have appropriate controls in place to manage sub-tier supplier IMDS submissions
any documentation submitted or received; and are aware whenever a sub-tier supplier makes a change that could require a new submission. E
9D IMDS - ensuring traceability of components before and after a material/substance of v
concern change or elimination; a
- updating the IMDS every time a significant variation of total weight of the l
product (>10%) occurs or a variation of the composition of the product u
(including surface treatments) occurs. a
t
i
o
n
w
i
t
h
a
9D IMDS

All parts undergoing the Process Audit shall have an approved IMDS * www.mdssystem.com
Prior to PPAP / Full Review timing for IMDS submission. Ensure Supplier is * Fiat Cap. 9.01102 – Fiat Cap. 9.01108 - EMEA /
submission. The Supplier is responsible for the IMDS data on their parts, as * IMDS Submission Prior to Pilot Builds Approval Review timing for IMDS submission. beginning to collect required information. Verify IMDS submission is complete.
well as sub-tier supplier data for materials/components. LATAM
 BACK TO PPA HIDE UNUSED ROWS SHOW ALL
MATRIX
BACK TO PPA
MATRIX HIDE UNUSED ROWS SHOW ALL

AUDITOR REMARKS (SQE)

BOX SCORE OPEN ISSUE / OBSERVATION CORRECTIVE ACTION RESPONSIBLE DEPARTMENT OPEN DATE TARGET DATE CLOSED DATE STATUS* COMMENTS
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Customer Approved Deviations

Box REQUIREMENT DEVIATION

Supplier Quality Engineer (Name/Date) Engineer (Name/Date) Supplier Quality Manager (Name/Date)

*Status: 25% Identified problem; 50% Action Plan proposed; 75% Action Plan implemented; 100% Solved issue
 Process Planning Review Kick-Off Meeting

Meeting Location: Date:

MY / Program: Supplier:
Parts / Description:

Item Topic Lead Time

Team Introductions - Core Team Members / Supporting Team

1 Members
2 PPR Meeting Cadence & Location
Team Responsibilities - Directed & Sub-Tier Supplier support, Open
3 Issue tracking, Core Team responsibilities, Support Team
responsibilities
4 Quality Risk Assessment (QRA) Review
5 Source Package Review - AQR, MPFMEA, & MFA

6 Program Timing Review - Major milestones and target dates (TKO,

OTOP, PDR, PA, PPAP, etc.)

7 Volume & Capacity Review - Planned volumes, operating pattern,

daily tooling capacity, expected PDR line speed requirements

8 Complete remaining PPR items

9 Complete Open Issues
10 Confirm next meeting

Attendees
Name Title / Company Name Title / Company
 Executive PPR Kick-Off Meeting
One Page Summary
HEADER
Supplier Name:
Supplier Code:
Model Year / Program:
Part Number(s):
Date of Meeting:
TEAM LIST
Supplier
VP of Quality:
Plant Manager:
Quality Manager:
Program/Project Manager:
Sales Manager:
Other:
Other:
Other:
Name Phone

BACKGROUND INFORMATION
QRA Program Risk:
Current Bid List Score:
TPSL / NBH:
Date of Last PA (if app.):

SOURCE PACKAGE & PART DESIGN

QUESTION YES PARTIAL NO
Have all applicable open issues from the Technical Review
been closed ("Green")?
Have all applicable open issues from the QRA been closed
("Green")?
Have all applicable concerns and open issues from the
MFA been closed ("Green")?
Is the quoted OEE value achievable with the planned
production process?
Has the Supplier reviewed and agreed to all requirements
in the AQR and Source Package?
Has the Supplier defined their Program Management
team, with adequate resources?
Does the Supplier have an adequate process for internal
and external communication?
Has the Supplier identified a single-point contact to
communicate roadblocks and critical issues?
 PROGRAM & TOOLING TIMING
QUESTION YES PARTIAL NO
Are the following deliverables expected to meet the program timing milestones?
Tooling Kick-of (TKO)
Gages & Measurement Devices complete
Tooling completion
Of-Tool Of-Process (OTOP)
PV / Self-Qualification Test Start
PV / Self-Qualification Test Complete
Production Demonstration Run (PDR)
PPAP / Full Approval
Have plans for the following deliverables been developed with adequate timing?
Error and Mistake Proofing
Sub-tier Supplier selection and quality planning
Sub-component approval
Is the Supplier's quoted tooling capacity sufficient to meet
launch ramp-up and planned production volumes?
Has the Supplier verified that all sub-tier Suppliers'
development timing (including required PA/PDR activity) is
sufficient to meet program milestones?
Have sub-tier Suppliers committed adequate capacity to
meet launch ramp-up and planned production volumes?
QUALITY IMPLEMENTATION
QUESTION YES PARTIAL NO
Does the Supplier's PFMEA process ensure that failure
modes from the DFMEA and MPFMEA are considered?
Has the Supplier agreed to implement all lessons learned
from the applicable MPFMEAs?
Does the Supplier's Control Plan creation process ensure
output from the PFMEA is addressed?
Does the Supplier have internal facilities for performing PV
/ Self-Qualification tests?
If no, do they use a certified sister facility or Third Party
Laboratory for testing?

Supplier Top Management: FCA SQ Manager: FCA Buyer / Commodity Manager:

Name:_____________________ Name:_______________________ Name:______________________

Sign. _____________________ Sign. ________________________ Sign. _______________________

PPR Kick-Off Meeting
Page Summary
HEADER
Supplier Location:
Region:
Commodity / BICEEP:
Part Description:
Date of Follow-up:
TEAM LIST
Customer
SQ VP or Director:
SQ Sr. Manager:
SQ Manager:
SQE:
Buyer / Commodity Mgr:
Buyer:
Engineer / R&D Mgr:
Engineer:
Name Phone

KGROUND INFORMATION
Initial PPR Score (if app.):
SEA Score (if app.):
TPSL / NBH Trend:
Last PA Score (if app.):

PACKAGE & PART DESIGN

COMMENTS / ACTIONS RESP. / DATE
RAM & TOOLING TIMING
COMMENTS / ACTIONS RESP. / DATE
nes?

ing?

LITY IMPLEMENTATION
COMMENTS / ACTIONS RESP. / DATE

FCA Buyer / Commodity Manager: FCA Engineering Manager:

Name:______________________ Name:_______________________

Sign. _______________________ Sign. ________________________

Score Classification Advance Quality Definition

• Very late to required milestone and will cause other required deliverables to
their required milestone/vehicle launch
• Risk Mitigation Plan does not exist
1 JOB STOPPER • Certain to cause delay in milestone/vehicle launch
• Has resulted in critical build/launch issues and certain to cause critical quali
production (yardholds, PRIs, field campaigns, etc.)
• Total lack of quality system or systemic control

• Late to required milestone and may cause other deliverables to be late to th

milestone/vehicle launch
• Risk Mitigation Plan exists but is not acceptable or requires unrealistic timin
JOB STOPPER milestone
2 RISK • May cause delay in milestone/vehicle launch
• Has resulted in moderate build/launch issues or may cause critical quality sp
production (yardholds, PRIs, field campaigns, etc.)
• Chronic quality system or systemic control failures

• Potentially late to required milestone

• Risk Mitigation Plan exists and is acceptable
• Moderate Risk to milestone/vehicle launch
3 MODERATE RISK • May result in moderate quality spills in production not impacting critical / sa
characteristics
• Non-chronic quality system or systemic control failures

• Progressing according to required milestone timing

4 LOW RISK • Low Risk to milestone/vehicle launch
• Isolated documentation issue

IMPLEMENTED
5 Complete and approved
ACTIVITY

NA NOT APPLICABLE Ite

NV NOT EVALUATED Item was not evalua
y Definition

ther required deliverables to be late to

nch
certain to cause critical quality spills in
)

r deliverables to be late to their required

or requires unrealistic timing to meet

r may cause critical quality spills in

)
res

tion not impacting critical / safety

failures

ming

Item does not apply for this audit

Item was not evaluated at this audit; will be evaluated at a later date.
 BACK TO PPA MATRIX
BACK TO PPA MATRIX

Current Production Definition

• Has resulted in critical quality spills (yardholds, PRIs, field campaigns, etc.)
• Corrective Action Plan does not exist.
• Results in process producing defective material with no adequate controls in place
• Total lack of quality system or systemic control

• Has resulted in moderate quality spills (NCTs, Bills, etc.) or may result in critical quality
spills in the future
• Corrective Action Plan exists but is not acceptable; needs containment action
• Can result in process producing defective material with inadequate controls in place
• Chronic quality system or systemic control failures

• May result in moderate quality spills in the future not impacting critical / safety
characteristics
• Corrective Action Plan exists and is acceptable
• Can result in process becoming unstable (may need additional controls added)
• Non-chronic quality system or systemic control failures

• Low risk for quality spills

• Corrective Action Plan / corrective actions initially implemented; verification on-going
• Continuous improvement activities ongoing
• Isolated documentation issue

• Complete and approved

• Best practice

es not apply for this audit

this audit; will be evaluated at a later date.
 BACK TO PPA
MATRIX
BACK TO PPA
MATRIX

Contact List
Attended
[Y/N] NAME COMPANY TITLE
Contact List
TELEPHONE MOBILE
NUMBER NUMBER
E-MAIL
Date Revision Number
01-Sep-14 1.0

19-Feb-15 1.1

30-Jun-15 1.2
06-Nov-15 2.0
18-Dec-15 2.1
Revision Description
Initial Release
Revised logo to FCA for all sectors
Revised sector names to regional names
Changed Open Issues to only hide rows that have received a "5"
Deactivated QRA Program Risk for EMEA / LATAM, APAC (EMEA / LATAM sourced), and Powertrain
(EMEA)
1D Special Characteristics: added "FPSC" and Strengthened Control Plan" to list of items critical
characteristics need to be included on

2D Tooling: revised requirements for marking tools for FCA US LLC (metal tags now acceptable)

3E Safe-Launch Activities: Added "(at least equivalent to that used by the Customer's CPA inspection
area)" to the first item; added "Data shall be collected by the Supplier and forwarded to the
Customer SQE and Plant."
4A Process Monitoring: added "When requested, copies of Boundary Samples shall be made
available to the Customer facility and quality personnel." in the 4th item.
Fixed 7B where "pages XX & XXX" in reference column is replaced with "Appendix B"
Updated Open Issues to allow selection of Box (allows more than one issue per box)
Updated "Customer" to "FCA"
1A - Commonized by adding MFA to all regions, and specifying SoR for EMEA/LATAM; added
references; revised QRA add providing Sourcing % for Quality First; changed target for completion to
"Prior to Source Selection"
1B - added requirement for DFMEA development procedure to include benchmarking and updating
for yardholds and field campaigns; changed target to start for second paragraph to "Initial design
concept"
1C - minor revision to second paragraph for clarity; third paragraph updated for commonality and
clarity.
1D - removed "Key Product Characteristics" as a designation (only "special" will be used); clarified
definition of special characteristics; revised to remove Part I/S final document; revised for clarity and
current characteristic classification

1E - added "- notification to the Customer of any risk or impact on timing, program milestones,
tooling, or resources;" and "- record or log of the first production shipment and retention of that
data for traceability;" to second item; clarified approval from FCA Engineering is required to make an
engineering change

2A - revised references; clarified deliverables in first paragraph; added requirement for Supplier to
update tooling status every 2 weeks minimum for "Ongoing PPR Activities"; added requirement to
identify TAG individual, when applicable
2B - combined Process Flow Diagram elements into a specific list
2C - updated PFMEA development procedure to match DFMEA development procedure; changed
EMEA/LATAM suggested completion to "Prior to TKO"; matched EMEA/LATAM requirements to
NAFTA requirements
2D - Added clarification to second paragraph that Readiness and Process Evaluation portions of the
Process Audit are required on production tools and process
2E - Removed "critical" from sub-tiers required to have backup plans; added "or process" to fourth
paragraph
3A - clarified in second paragraph that the Control Plan Process Audit checklist is a NAFTA
requirement; removed requirements for Final Part I/S

3B - clarified that a PDR is also required (besides PA) on sub-tier Suppliers for Sel-Qualification

3D - Added "When required by FCA, gages shall be built to reflect the part in actual vehicle position."
to the first paragraph; added "Determine which gages, if any, need to be built to reflect the part in
vehicle position." to "PPR Kick-Of Meeting Activities" in the first line; rewrote paragraph 4 as a
checklist for clarification; added requirements from fourth paragraph into first paragraph and
deleted fourth
3E - Rewritten to commonize as SLP
4A - changed approvals required for Appearance Manual / Boundary samples to read (paragraph 3):
"Approval shall include Plant Perceived Quality (CPA), plus other appropriate Customer
representatives (SQ, Engineering, Corporate Quality, etc.).;
4B - added requirement to adhere to CQI-8 to first paragraph; added clarification statement to thrid
paragraph that the E/M-proofing audit shall be performed prior to the PDR

4E - added "- ESD production areas separated from other areas of the facility, with climate controls
as necessary;" to first paragraph; added "Suppliers with other special processes (e.g., heat treating,
plating, painting, etc.) shall have a process in place that includes the following:
- Operator training and certification;
- Inclusion of the process in the Supplier's LPA program;
- Conducting self-assessments to industry standards (as required);
- Process monitoring and data recording requirements." to second paragraph

5B - added " based on past history, AQR, MPFMEA, PFMEA, etc." to first bullet of the first paragraph

5C - added "- criteria for determination of what parts shall undergo rework/repair (as opposed to
being scrapped);" to first paragraph
5E - deleted second paragraph regarding ISO 14001 (this is still a requirement, but is out of scope for
PPR or PA); clarified that the Fire Prevention License is EMEA requirement
7B - added reference to performance tab
7D - added definition of 3CPR as NAFTA and CSL as EMEA/LATAM; clarified deviation must be
approved by FCA Engineer; clarified CQMS note in last paragraph applies to NAFTA
8A - added "LUA/LUR" to examples of tools, "with clear target dates and escalation procedures when
target dates are not met", and "Work Instructions" to list of quality documents needing to be
updated; added clarification to second paragraph of Customer responsibility; added GIMS and SQP
to list of systems
8B - added FR to list of quality requirements
8D - added clarification that NAFTA Suppliers must meet AIAG CQI-14
8E - changed reference link for SQP to access via eSupplierConnect.com
9A - added second paragraph regarding reliability to EMEA/LATAM users;
Added Performance Requirements chart
Added tab for Executive PPR Kick-Of form
Made "QRA Program Risk" on Matrix viewable for all regions
Added tab for Sample PPR Kick Of agenda
Sheet
All
All
All
Open Issues

PPA Matrix

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Open Issues
Entire document

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Requirements Worksheet
Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Requirements Worksheet
Requirements Worksheet
Requirements Worksheet
Performance Requirements
Executive PPR KO
PPA Matrix
Sample PPR KO Agenda