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Welcome to.Planning forPlanning for
ProcessProcessSignSign--OffOff
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Slide 3
Rules for
Lego ActivityFor your Table (Team):
Build one racing car model
Every team member must be involvedin assembling the racing car
Plan your build
Picture & documentation is in envelope
Your team has 10 minutes.
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Slide 4
What is PSO?A systematic and sequential review of the
Suppliers planned and actual manufacturing
process at the quoted peak daily line rate,
including:Manpower Methods
Facilities Procedures
Equipment Software Level
Material Tooling
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Slide 5
Todays Agenda
1. PSO Strategy
2. Pre-PSO
Documentation Review
3. Pre-PSO Supplier
Readiness Evaluation
4. PSO on-site Visit
5. Post PSO visit
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Slide 6
LogisticsLogistics
Breaks & Lunch
Location of Restrooms Turn off Cell Phones
Ground Rules
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Slide 7
Process Sign-Off Strategy
PrePre PSOPSO Review Requirements
Documentation Review
Supplier Readiness Evaluation
PSO OnPSO On--Site VisitSite Visit Witness Production DemonstrationRun
PV & Packaging Shipping Testing
Complete Sign-off
PostPost PSOPSO PPAP Warrant
Continuous ConformanceRequirements
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Slide 8
Scope of Process Sign Off
Why: Verify supplier quality planningprocess & production processesare capable of producing qualityparts in sufficient quantity
Who: Product Team Members &
SupplierWhen: Starts early in CDS process, PSO
sign-off shall occur prior to S1,CC throughout the life ofprogram
How: Pre-PSO Documentation Review,PSO on-site visit and Post PSOrequirements
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Slide 9
Risk Drivers
Part RiskAQP Activity
LevelPAP PSO
Low Self Directed SupplierLed
SupplierLed
Medium Collaborative Supplier DCX
High Directed DCX DCX
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Slide 10
Where do PSO elements fit into CDS timeline?
PPDC
D2EFG1 G2
FinalSpecs
(Lastenheft
)
S0 Start S1 St artS1 End
S2 Start
D1 C
S2 End
& V1H
(165) Wks (143) Wks (121) Wks (104) Wks (78) Wks
Theme
Selection
(35) Wks
SO EndPre Specs
(Rahmenheft)
A
(22) Wks (10 ) Wks
#1 Part Number, Description
PostV1
#6 Control Plan
#2 Design FMEA
#3 Test Sample Sizes and Frequencies (DVP&R Plan & DV Testing)
#4 Process FMEA
#1.4 Engineering Standards(CATIA Comments Page)
#5 Process Flow Diagram/Floor Plan
#9 Parts Handling Plan
#10 Operating Instructions
#11 Tooling/Gages Identified
#14 Error/Mistake Proofing Plan
#19 Parts Packaging/Shipping Plan
#16 Evidence of Product Specification
(SRE Run Results)
#20 Gage & Test Equip. Evaluation
#17 Line Speed Demonstration
#15 LPA Plan
#22 Initial Process Study
#24 PV Testing Complete
Initial Risk Evaluation (IRE)
PPAP
CP25 Disclose Parts in EBOM
OD210 Production Release Design
OD50 Complete DFMEA
OD100 Complete PFMEA
OD160 Define Material Handling Plan
VF30 Complete DV & PV Testing
OD160 Define Material Handling Plan
OD220 Tooling/Equipment Design CompleteOD140 Complete Gage, Fixture, Test Equipment & Mistake Proofing Requirements & Test Plan
VF116 Complete Production Control Plan
VD150 Verify Work Station Designs & Operation Descriptions
OD140 Mistake Proofing Requirements & Test Plan
OD90 Complete Process Design
VF30 Complete DV & PVTesting
VF130 Complete PSO
CP50 Conduct Supplier Initial Risk Evaluation
(0) Wks
LEGEND
Yellow = PSO Element
Requirement
Red = Non-PSOactivity
Note: PSO ElementRequirement isfollowed bycorresponding PAPTask.
B Z
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Slide 11
Process Sign-Off Strategy
PrePre PSOPSO Review Requirements
Documentation Review
Supplier Readiness Evaluation
PSO OnPSO On--Site VisitSite Visit Witness Production Demonstration
Run
PV & Packaging Shipping Testing
Complete Sign-off
PostPost PSOPSO PPAP Warrant
Continuous ConformanceRequirements
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Slide 12
Module 2: Pre-PSO
Documentation Review
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Slide 14
Some Changes from PSO 4
Summary Report is now 3 pages
PSO elements are in logical order
Each element has checkbox to indicateaccept or re ect
Each sub-element has its own yes orno checkbox
Documents with * review during AQP &again in Pre-PSO Document Review
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Slide 15
PSO Plan Activity
Ah, Grasshopper..At your table, drawing from your PSO experience:
What are some of the things you have foundthat have served you well?
What has caused you problems?
One piece of advice to a new SQS?
Flip chart your responses.
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Slide 16
PSO Process Elements Verified During On-Site Visit
Documentation
1. PART N MBER, Accept RejectDESCRIPTION &
CHANGE LEVELYes No
* Cross-reference sheet
[if applicable]
1.4 Engineering Standards
Identified
* CATIA Comments Page
with list of applicable
standards
(e.g. DCC. Environmental, etc.)
Process
Accept Reject
Yes No
Acceptable supplier
change notice
procedure
Evidence of customer
change notice
Process for obtaining
the latest revisions of
standards
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Slide 17
Element 1 Differences
Procedure to ensure Supplier has latest
Engineering Standard revision level
A system in place to notify all applicable
departments of specification changes as they
occur
erify change notice procedure is cascaded
down through Extended Enterprise 2 downthrough Extended Enterprise 2nd & 3rd Tier
Suppliers
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Slide 18
PSO Process Elements Verified During On-Site Visit
Documentation
2. DESIGN FMEA Accept Reject
Yes No
* Design FMEA
complete &
acceptable
Process
Accept Reject
Yes No
DFMEA updated
to include
applicable DV
failures
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Slide 19
FMEA Driven Reaction Plan
RPN = Severityx Occurrencex Detection
DCXGuidelinesUse a Rolling Top 20 Paretomethodology, give specialattention to:Severity =8, 9, 10
Severity =>5 withOccurrence =>2
Detection = 10
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Slide 20
Element 2 Differences
MEA done with latest A AG guidelines
MEA best practice document and
communication process shall bereviewed periodically
Re-verify Design MEA after any D &
P failures Reaction Plan
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Slide 21
PSO Process Elements Verified During On-Site Visit
Documentation
3. TEST SAMPLE Accept RejectSI ES &FREQ ENCIES
Yes No
* Signed DV & PV plans
* Signed DVP&R
[DV complete]
* Signed Waivers
[if applicable]
Process
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Slide 22
Element 3 Differences
oth D & P and D P&R have to be signed
by DaimlerChrysler engineering
Must have signed waiver if D has any
deviations
ailures must be addressed with Daimler
Chrysler 8-Step Corrective Action form
Supplier must have Test to ailure plan
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Slide 23
PSO Process Elements Verified During On-Site Visit
Documentation
4. PROCESS Accept RejectFMEA
Yes No
* Process FMEA
completed
& acceptable
Process
Accept Reject
Yes No
Process correlates
with occurrence
and detection
numbers on PFMEA
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Slide 24
Element 4 Differences
MEA done with latest A AG guidelines
MEA best practice document and
communication process shall bereviewed periodically
Re-verify Process MEA after any D &
P failures Reaction Plan
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Slide 25
Common FMEA Mistakes:
Some Rules to Follow
Common Mistakes
No clearly defined MEA scope
Process Causes or Controls Used
Root Cause not dentified
orget to use Error MistakeProofing
Setting Arbitrary Thresholds
Too ague Not Detailed
Too Late
Not Updated
Some Rules State the failure effects in termsof what the customer(mightnotice or experience.
Potential cause is how the failure
couldoccur. Elimination of specified potential
causes should result in areduction in RPN it is a checktoensure you found theengineering root cause. The
severityw
ill remain the same.
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Slide 26
asic MEA Evaluation Questions
To prepare for Quality Gates ask these questions Are all of ma or functions represented?
Have you used historical data to identify all potential failure modes? Are they
detailed and specific?
Are the effects to the customer described in detail? s the severity rate
correctly evaluated?
Are the potential causes detailed enough? Do they include how, when, whereand what failed?
Does the current controls detect the cause?
When was the MEA last updated? s it up to the latest design date?
Are high RPNs being addressed?
What tests were used to validate corrective action?
Are responsibilities and completion dates listed for recommended actions?
s there evidence of error mistake proofing?
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Slide 27
PSO Process Elements Verified During On-Site Visit
Documentation
5. PROCESS FLOW Accept RejectDIAGRAM &MFG FLOOR PLAN
Yes No
* Flow Diagram
* Manufacturing Floor Plan
* Work Station Layout
Process
Accept Reject
Yes No
SPC operations
identified on flow
diagram
nique equipment
numbers identified
on mfg floor plan,
flow diagram, or
workstation layout
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Slide 28
Element 5 Differences
dentification of stations that measure
key characteristics shall be clearly
identified on flow diagram Unique identification machine numbers
shall be identified on the manufacturing
floor plan, flow diagram or work station
layout
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Slide 29
PSO Process Elements Verified During On-Site Visit
Documentation
6. CONTROL PLAN Accept Reject
Yes No
* Process characteristics
identified on the Control
Plan
* Verification ofMistake
Proofing on
Control Plan
Process
Accept Reject
Yes No
Proper adherence to
Control Plan
Rework / Repair
stations have
acceptable controls
[if applicable]
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Slide 30
Control Plan Evaluation Criteria Does it align with the process flow diagram?
Does it reference DFMEA or PFMEA?
Does it have Mistake Proofing or Error Proofingmethods?
Does the reaction plan procedure have more than tonotify the supervisor?
Does what they are controlling make sense for theprocess? How was it determined?
Will the sample size and frequency be sufficient to
identify problems early enough?
What continuous improvement plan do they have inplace?
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Slide 31
Element 6 Differences
nclude Mistake Proofing verification
More attention on rework repair operations
they shall have controls equivalent to the
primary line
A mechanism which links the Suppliers
D MEA & P MEA to the Control Plan
Supplier shall look at the High Severity Zone &Potential High Warranty Zone to ensure that they
are addressed
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Slide 32
PSO Process Elements Verified During On-Site Visit
Documentation7. Q ALITY Accept Reject
PLANNING
Yes No
* Completed PAP/APQP
PSO Summary Matrix
7.2 Supply Base Management* Easy Map, etc.
Risk sub-components
Level 3 PPAP data
7.3 Problem Solving Methods* Example of a DOE, etc.
2 SIDs for DCC systems
* Example of a problem solving
technique
Process
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Slide 33
Element 7 Differences
Quality Planning now includes Supply ase
Management & Problem Solving Methods
Supplier shall risk all components listed on
the ill of Material
PSO activities to be done for medium & high risk
sub-components
Sub-tiers to submit level 3 PPAP documentation
along with line speed demonstration results
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Slide 34
Element 7 Differences, cont
Communication Plan for lessons learnedacross production lines within Suppliersfacility and other Supplier facilities which ship
product to DaimlerChrysler DOEs or other acceptable methods of
process optimization
Problem solving methods should be verified
by specialist A minimum of two S Ds shall be obtained for the
DaimlerChrysler problem solving systems e-C MS
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Slide 35
PSO Process Elements Verified During On-Site Visit
Documentation
8. INCOMING MATERIAL Accept Reject
Q ALIF / CERT
PLANYes No
Certificates of Analysis
Copies of sub-tier PSWs
* Plan for lot control
* Plan for traceability
Process
Accept Reject
Yes No
Evidence of sub-tier
monitoring
Proof of lot control
Proof of traceability
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Slide 36
Element 8 Differences
DaimlerChrysler requires use of the Lot
Sampling Table or Supplier can use 2 or
more inspection requirements in TS-16949
section 7 4 3
Dock to Stock no incoming inspection is
dependent on receiving 3 shipments without
defects or external complaints Supplier shall
have documentation to support requirement
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Slide 37
PSO Process Elements Verified During On-Site Visit
Documentation
9. PARTS HANDLING Accept RejectPLAN
Yes No
* Routing/Traveler Cards
* Parts Handling Plan
* ContainerMaintenance
Plan
Process
Accept Reject
Yes No
Evidence of acceptable
parts handling
Acceptable method of
inventory control
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Slide 38
Element 9 Differences
Documented plan on how parts are managed& tracked throughout entire manufacturingprocess
Should address segregation & identification ofscrap, rework repair and W P
f Suppliers traceability system depends ontheir O system, then all sub-tiers shall use
O as well
Document how containers are inspected &repaired
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Slide 39
Element 9 Differences, cont
Acceptable method of inventory control
for Work n Process
Acceptable method of inventory controlfor returnable dunnage
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Slide 40
PSO Process Elements Verified During On-Site Visit
Documentation
10. OPERATING Accept RejectINSTR CTIONS
Yes No
* Work Instructions
* Inspection Instructions
* Rework/Repair Instructions
Process
Accept Reject
Yes No
Visual displays clearly
present at each station
Operators follow
work instructions
Evidence of proper
operator training
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Slide 41
Element 10 Differences
Operating nstructions shall be approved bySuppliers cross functional team, includingoperators
A robust process of training and qualifyingoperators prior to operators performingproduction processes shall exist List of Training requirements for each unique
workstation
isual inspection stations shall have methodsestablished to verify operators ability to finddefects i e periodic testing, re-certification
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Slide 42
PSO Process Elements Verified During On-Site Visit
Documentation
Accept Reject
11. TOOLING EQ IPMENT
& GAGES IDENTIFIED
Yes No
* Tooling & Equipment List
* Supplier Tool Record
Process
Accept Reject
Yes No
STR in agreement with
Suppliers manufacturing
facility
DCC ownership tags
present
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Slide 43
Element 11 Differences
During on-site PSO visit, SQS verify all gagesfixtures listed on STR Supplier Tool Recordare present on Suppliers manufacturing floor
When tooling is purchased for Tier 2s Tier 3s,verify the STR states the appropriate location
All tooling, gages, fixtures and capitalequipment required to produce a productshall be identified and appear on a tooling list
All DaimlerChrysler owned tooling, gages andfixtures shall be permanently tagged per AME84-206-0021 GR GR&R Tag
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Slide 44
PSO Process Elements Verified During On-Site Visit
Documentation
12. SPECIAL PROD CT Accept Reject& PROCESSCHARACTERISTICS
IDENTIFIEDYes No
* First Production ShipmentCertification (FPSC ) planacceptable &
contains special
process & product
characteristics
Process
Accept Reject
Yes No
SPC performed for
identified
Special Characteristics
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Slide 45
Element 12 Differences
All DaimlerChrysler directed sub-tiers
shall abide by the same PSC quantity
requirements as DaimlerChrysler Tier 1
Tier 1-> 2 DCC Assembly plant = 2000
pieces; directed Tier 2 = 2000 pieces
Completed PSC shall be reviewed with
the DaimlerChrysler PSO team PostPSO activity
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Slide 46
PSO Process Elements Verified During On-Site Visit
Documentation
13. PROCESS Accept RejectMONITORING
Yes No
* Control charts
* 1st piece approval
procedure
Process
Accept Reject
Yes No
Acceptable 1st piece
approval process
1st piece approval records
Control &
Performance Charts
maintained appropriately
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Slide 47
Element 13 Differences
Targets for TC, Scrap and Rework to beidentified and documented Plans to improve TC, scrap and rework shall be
documented PSO Team shall approve all Rework Repair
operations, procedures and work instructions
Must have acceptable irst Piece Approvalprocess irst piece retained until end of production run
Documented evidence of its execution maintained
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Slide 48
PSO Process Elements Verified During On-Site Visit
Documentation
14. ERROR & Accept RejectMISTAKEPROOFING
Yes No* Error & Mistake
Proofing Plan
* List of Error &Mistake Proofing
Process
Accept Reject
Yes No
Boundary samples
created & utilized
Mistake proofing
contingency plan
with visual/audiblealarm
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Slide 49
Element 14 Differences
More detailed Element description
MEA Severity >8 & all Special Product ProcessCharacteristics have Error Mistake Proofing
Error Mistake Proofing with Line Station Lock-out toensure defects dont reach next operation
Audible and isual indicators shall notify operator ofthe failed operation
Supplier create oundary Samples for processverification and agreed upon by PSO Team oundary samples to include known conforming and
non-conforming; Appearance Master Samples, etc
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Slide 50
PSO Process Elements Verified During On-Site Visit
Documentation
15. LAYERED Accept Reject
PROCESS
A DIT PLANYes No
* Acceptable LPA plan
* Frequency & structure
chart
Process
Accept Reject
Yes No
Acceptable LPA
performed
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Slide 51
Layered Process Audit LPA
LPA is an ongoing system of process checks, that verify
proper methods, settings, operator craftsmanship, error
proofing devices and other inputs are in place to ensure
a defect free product.
How does LPA work?
Process Audits are conduct bylooking at:
1) Build Technique2) Error Proofing
3) Machining Attributes
Encourages ManagementInvolvement:
Production Supervisor [1x shift] Area Management [2 x week]
Plant Manager [1 x week]
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Slide 52
LPA enefits
Reduces
Build variation based on work
standardization
End-of-line inspection
Part defectsImproves First time through capability
Morale
Facilitates Operator training
Management operator interface
Reinforces Safety regulations
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Slide 53
LPA Compliance erification
Documentation Review:
LPA Roll-out Timing Plan
LPA Procedures
LPA Work Instructions LPA Structure & Frequency Chart
LPA Process Control Audit Checklist
LPA Error Proofing Verifications Checklist
LPA Compliance Form: To be submittedmonthlyto SQ Specialist
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Slide 54
PSO Process Elements Verified During On-Site Visit
Documentation
16. EVIDENCE OF Accept Reject
PROD CT
SPECIFICATIONSYes No
* Supplier Readiness
Evaluation Completed
and Acceptable
Process
Accept Reject
Yes No
Completed & acceptable
Measurement System
Verification Report
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Slide 55
Element 16 Differences
Supplier Readiness Evaluation form Supplier is required to perform Readiness
Evaluation run SRE at the production line speed
RecordF
irst Time Capability, Gage R&R, etc Recommendation for Suppliers to submit
PSO Summary Matrix required forBody &White with SRE form for PSO review
Compliance Report revised to MeasurementSystem erification Report Approve Suppliers process for measuring
product process characteristics
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Slide 56
PSO Process Elements Verified During On-Site Visit
Documentation
17. LINE SPEED Accept Reject
DEMONSTRATION
Process
Accept Reject
Yes No
Contingency plan
forBottlenecks
[if applicable]
Line Speed Observed:_______ FTC:_____
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Slide 57
Element 17 Differences
PSO team to compare Quoted Tooling
Capacity to the Daily Capacity Planning
olume
f there is a discrepancy between the two
numbers, the PSO team shall meet with
the DaimlerChryslerBuyer and the
Supplier to determine the required PSOline speed
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Slide 58
PSO Process Elements Verified During On-Site Visit
Documentation
18. O TGOING Accept RejectQ ALIFICATIONPLAN
Yes No
* Outgoing inspection
plan
* Part inspectionstandard
Process
Accept Reject
Yes No
Evidence of
non-conformance
containment
Evidence of outgoing
audits [using part
inspection standard]
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Slide 59
Element 18 Differences
Part nspection Standards are required for allKey parts as identified by Engineering Standard list all Product Characteristics inspected
by Supplier on finished product prior to shipment Outgoing Qualification Plan include Forever
Requirements Supplier Notification of Potential Non-
Conformance Process
Documented evidence of outgoing auditsusing the Part nspection Standard and
Containment Records
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Slide 60
PSO Process Elements Verified During On-Site Visit
Documentation
19. PARTS PACKAGING Accept Reject& SHIPPINGSPECIFICATIONS
Yes No
* Dunnage design
sign-off from MHE
[if applicable]
* Packaging & shipping
plan
Process
Accept Reject
Yes No
Acceptable container
management
plan
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Slide 61
Element 19 Differences
Material Handling requirement shall
include a Unit Load Data ULD sheet
for Supplier designed dunnage approval
DaimlerChrysler directed 3rd party
dunnage suppliers do not need MHE
design approval
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Slide 62
PSO Process Elements Verified During On-Site Visit
Documentation
20. GAGE & Accept RejectTEST EQ IPMENTEVAL ATION
Yes No* Gage R&R studies
* Calibration plan &
schedule
Process
Accept Reject
Yes No
Appropriate gages
used in the
process
Calibration performed
according to schedule
NOTE: The gage plan must explain howthe
gage was determined.
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Slide 63
Element 20 Differences
More detailed Element description
Effective system to ensure calibration ofequipment done per schedule
Reaction Plan for containment ofequipment that is out of calibration
A Gage Plan that explains how
appropriate gage for process isdetermined
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Slide 64
Element 20 Differences, cont
All gages used in the process shall be
identified on Control Plan
RPNs reduced by measuring gaugingshall have an acceptable gage
evaluation and calibration frequency
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Slide 65
Measurement System erification Report
CHANGELEVEL(S)P
PRE-PSO MEETING DATE
PSO ON-SITE VISIT DATE / NUMBER
Q
Q
Q
Q
Q
Q
R
S
Joe SchmoeMary Smith
John Doe
Bushing- Sw age Toe Link Bush
1/5/05
LX
99999AF
11/19/04
T. Automotive
Somewhere, MI
04885735AA
Refer to the Ppk Capability Matrix (Appendix B of the PSO 5th Edition Manual ) for Ppk requirements.
DATA
SUMMARY EXAMPLE
1.6/1.7
2.2/2.3
P P / P PKP
Length
Hole Size
(3.6 - 7.5 mm)
(2.0 0.02 mm)
CALIPER
CMM MACHINE
30
30
100%
93%
QUANTI TY
ACCE P TE D
30
28
FT C
P E RCE NTAGE
(without repair)
CH AR AC TER IST IC SP EC IF IC AT IONM E THOD OF
M E AS URE M E NT
QUANTI TY
A T T E M P T E D
COMMENTS:
End of Inner to End of Outer 4.5 +/- 0.8 caliper 2.94/2.93
4.89/3.65
4.63/2.95Outer Metal O.D. 40.30 +/- 0.1 caliper 30
Inner Metal I.D. 12.20 +/- 0.10 caliper 30
PQUANTI TY
A T T E M P T E D
Number of parts witnessed: Witnessed By:
CH AR AC TER IST IC SP EC IF IC AT IONM E THOD OF
M E AS URE M E NTP P / P PK
FT C
P E RCE NTAGE
(without repair)
QUANTI TY
ACCE P TE D
the number of characteristics selected depends upon the complexity.
Variable data is preferred but attribute data is acceptable.
MEASUREMENT SYSTEM VERIFICATION REPORT
As part of the PSO, the actual measurem ent process must be w itnessed by the PSO Team.
A minimum of 3 characteristics are to be checked. For any given part, assembly, or process,
A minimum of 30 randomly selected samples s hall be checked during the PSO on-site visit.
SUPPLIER PROGRAMMFG. LOCATION SUPPLIER CODE
PART NUMBER(S) PART NAME(S)
For attribute data, a 30 piece sample with one or more non-conformances is unacceptable.
All deviations shall be listed in the COMMENTS section of this document.
30
93%
100%
97%
28
30
29
PSO
DaimlerChrysl
5th Edition
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Slide 66
Repeatability & Reproducibility:
Some Rulesf repeatability is large compared to reproducibility thereasons may be:
nstrument needs maintenance
Gage may need to be redesigned to be more rigid
Clamping or location for gaging needs to be improved Excessive within part variation
f reproducibility is large compared to repeatability, thereasons may be:
Appraiser needs further training on how to use & read gage
Calibrations on gage dial are not clear
A fixture may be needed to help appraiser use the gagemore consistently
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Slide 67
PSO Process Elements Verified During On-Site Visit
Documentation
21. PREVENTIVE Accept RejectMAINTENANCEPLANS
Yes No* PM Plan
* PM Schedule
* PM Procedures/Work
Instructions
Process
Accept Reject
Yes No
PM performed
according to schedule
Robust PM Process
All tooling/equipmenton PM schedule
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Slide 68
Element 21 Differences
PM plan to incorporate lessons learned from
prior production lines or Tooling Equipment
related Quality concerns
Addresses 3rd party outsourced PMrequirements
Activities shall be identified on the schedule
PM process equal to or better than that of the
Supplier
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Slide 69
PSO Process Elements Verified During On-Site Visit
Documentation
22. INITIAL Accept RejectPROCESSST DY
Yes No Deviations [if applicable]
Sample size:_______ PpK requirement:_____
Process
Accept Reject
Yes No
Acceptable First
Time Capability
Acceptable Process
Capability
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Slide 70
Element 22 Differences
Modified form Expanded to incorporate more information from
Production Demonstration Run e g USL, LSL,UCL, LCL
FTC requirement of 90% or greater < 90% needs approval of SQA Quality Manager
Capability Matrix shall be used for those whodeviate from nitial Process Study samplesize requirements Ppk is based on sample size agreed upon by the
PSO team
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Slide 72
PSO Process Elements Required ForFull Approval
Documentation
23. PACKAGING Accept RejectSHIPPINGTEST APPROVAL
Yes No Signed shipping /
simulation test
approval
[MHE LD sheet]
Process
Accept Reject
Yes No
Shipping/simulation
testing completed
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Slide 73
New Element
Packaging shipping test results require
Corporate and Assembly Plant Material
Handling Engineering approval
Simulation test results require CorporateMaterial Handling Engineering approval
DaimlerChrysler directed 3rd party dunnage
shall have shipping simulation testing
performed
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Slide 74
PSO Process Elements Required ForFull Approval
Documentation
24. PROD CTION Accept RejectVALIDATIONTESTING COMPLETE
Yes No
Signed DVP&R
[PV complete]
Signed Waivers
[if applicable]
Process
Accept Reject
Yes No
BSR/NVH testing
complete
PV test completed
Repair/rework process
validation completed
[if applicable]
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Slide 75
Element 24 Differences
ncludes BSR N H
Requires Engineering signatureapproval of P test plans
Requires Engineering signatureapproval of P test results D P&R
P testing must include parts from
rework repair process whereapplicable
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Slide 76
PSO Process Elements Required ForFull Approval
Documentation
25. CONTIN O S Accept RejectCONFORMANCE (CC)
Yes No
Continuous
Conformance Team
identified & Trained
Warranty process
flow diagram Forever Requirements
submission procedure
Process
Accept Reject
Yes No CC team is sufficient
to support Post-PSO
activities
Acceptable process
for warranty analysis
Family PV testing
agreed to by the
PSO team
Vehicle Families included in familyPV:______________________
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Slide 77
Element 25 Differences
Service Requirements now identified forDesign & Serviceability
Suppliers required to identify resources for
Life of Program ncludes:
Layered Process Audit uploads required quarterlyfor life of program
3CPR 3rd Party erification Audit requirements Warranty requirements
Forever Requirements
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Slide 79
Module 3: Pre- PSO Supplier
Readiness Evaluation
Supplier Readiness
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Slide 80
Supplier Readiness
Evaluation purpose First documented build attempt
Provide pre-production datausually minimum of 30 pieces
Confirm process is:
Set-up
Debugged
Ready for ProductionDemonstration Run
Supplier Readiness
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Slide 81
Supplier Readiness
Evaluation Data
Confirms proper setup, operation and
performance of installed production line
This data is used to estimate: Production rates
FTC
ields Pp and Ppk for special characteristics
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Slide 83
Process Sign-Off StrategyPrePre PSOPSO
Review Requirements
Documentation Review
Supplier Readiness Evaluation
PSO OnPSO On--Site VisitSite Visit Witness Production Demonstration
Run
PV & Packaging Shipping Testing
Complete Sign-off
PostPost PSOPSO PPAP Warrant
Continuous ConformanceRequirements
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Slide 84
Module 4: PSO on-site isit
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Slide 85
PSO on-site Visit purpose Witness build using production tools
Run must meet quality & production rate
requirements
PSO Team observes first 22 elementsof the PSO Summary Report
Success will result in parts for
Production alidation testing
PSO on-site Visit is
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Slide 86
PSO on site Visit is
conducted
Kick-off Meeting with appropriate plantmanagement to discuss:
Purpose
Agenda for Day
Observing Production DemonstrationRun
Closing Meeting to review results ofassessment
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Slide 87
DaimlerChrysler Process Sign-Off Summary
Report
4
ES N O
ES OP T ION
1 PARTNUM
ER DESCRIPTIONAND
ccep
ejec
ccep
ejec
C
ANGELEVEL
*Cross reference sheet Yes
o A ccepta
le Supplier change Yes
o
(IF
LI
BL
)
notice proce
ure
14 Engineering Stan
ar
s Identified Ev idence of custo mer change
Yes
o notice procedure
*C A TI A comments page
Process for o taining the Yes
o
ith list of applica
le standards latest standard re v ision
(e.g
VI
M
L e
c)
ccep
ejec
ccep
ejec
2 DESIGNFMEA
*Design F M E A complete Yes
o D F M E A updat ed to include Yes
o
accepta
le
applica
le D V failures
ccep
ejec
3 TEST SAMPLE SIZES AND FREQUENCIES
Yes
o
*Signed D V an d P V plans
*Signed D VP
R (D V complete)
*Signed
ai ver s
/
PARTNUM
ER(S)
MFGLOCATION SUPPLIER CODE
PART NAME(S)
Some
hereMI
04885735
99999
F
Bushing- S
age
oe Link Bush
C
ANGELEVEL(S) PRE-PSO MEETING DATE
PSO PROCESS ELEMENTS
* Documents
ith asterisk should
e re vie
edduring AQP meetings and again during the Pre-PSO Documentation Revie
PROGRAM _L
_______________________
B
PSO ON-SITEVISIT DATENUM
ER__01/05/2005____
11/19/04
DAIMLERC R SLER PROCESS SIGN-OFF SUMMAR REPORTALL PROCESS SIGN-OFF ELEMENTS APPROVED:
SUPPLIER
PSO EXTENDED RUN:
N O
.
u
omo
i
e
DOCUM E N T A T ION P R OC ESS
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Module 5:
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Slide 89
Module 5:
Post-PSOPrePre PSOPSO Review Requirements
Documentation Review
Supplier Readiness Evaluation
PSO OnPSO On--Site VisitSite Visit Witness Production Demonstration
Run
PV & Packaging Shipping Testing
Complete Sign-off
PostPost PSOPSO PPAP Warrant
Continuous ConformanceRequirements
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Slide 90
Continuous Conformance
Support
La ere Proce Audit
Proble Solving Methods Warranty
Annual Validation
Forever Require ents
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Slide 91
PSO 5th Edition Layout
ntroduction & Strategy
PSO Element Description
PSO Element Requirements
PSO Forms Commodity Specific Requirements
Guidelines for New SpecialistSuppliers
PSO Worksheets
Appendix
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Slid 92
Workshop Ob ectives1 Explain and apply the PSO Strategy; including purpose, requirements and
procedure for each step
2 dentify the required tasks and uses for each of the 25 Checklist Elements onthe PSO Sign-off Summary Report for both the Documentation and Processside
3 Demonstrate how to evaluate some of the ma or forms used to ensure aquality product
4 Describe the new guidelines for design and process FMEA
5 Describe the requirements involved in a Layered Process Audit
6 Develop a plan on how to accomplish all the elements on the PSO SummaryReport
7 Determine if a supplier is ready for the PSO on-site visit based on evaluationof the SRE documentation
8 dentify observations that could be made during a Demonstration of aProduction Run
9 Evaluate certain documentation requirements during the demonstration of thesuppliers production run
10 Plan how to ensure quality products throughout the life of the program