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Ford Proprietary Q1 Site Assessment Instructions
Q1 2002 Site Asessment Evaluation Matrix
1) The Q1 Site Assessment Evaluation Matrix is a 'checklist' used to provide objective evidence that satisfies
the Q1 Site Expections addressed in Q1 2002, Appendix C.
2) Suppliers are required to provide the completed 'checklist' to the responsible STA engineer upon request.
3) Suppliers are required to keep completed copies of the Q1 2002 Site Assessment checklist, and
accompanying corrective action plans, covering the prior 24 months. These copies are to be maintained
at the supplier manufacturing location and available upon request from the responsible STA engineer.
4) Score each sub-element with R/Y/G and the Expectation ranking will automatically be calculated. If you
receive an "INC" in the Expectation ranking, one of the sub-elements was not scored.
Originator: Laura Blair Johnson (lblair@ford.com)
File: f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls Date Created: 11/20/02
Instructions Page 1 of 31 Pages Date Revised: 11/30/2010
LIST OF ACRONYMS USED IN THE Q1 SITE ASSESSMENT
1PP (First Phase of Production Prove-Out)
AIAG (Automotive Industry Action Group)
AIMS (Automated Issues Matrix System)
APQP (Advanced Product and Quality Planning)
AWS (Analytical Warranty System)
BTS (Build-To-Schedule)
C&E (Cause and Effect)
CAD/CAM (Computer-Aided Design/Computer-Aided Manufacturing)
CC (Critical Characteristic)
CP (Confirmation Prototype)
Cpk (Process Capability Index)
CPU (Cost Per Unit)
CPV (Capacity Planning Volume)
CTQ Critical to Quality
DCP (Dynamic Control Planning)
DDL (Direct Data Link)
DFMEA (Design Failure Modes & Effects Analysis)
DMAIC (Define, Measure, Analyze, Improve, Control -- 6 Sigma Problem solving)
DPMO (Defect per Million Opportunities)
DPU (Defect per Unit)
DTD (Dock-To-Dock)
DVP&R (Design Verification Plan and Report)
ES (Engineering Specifications)
FCPA (Ford Consumer Product Audit)
FMEA (Failure Mode and Effects Analysis)
FSN (Ford Supplier Network)
FSP (Ford Supplier Portal)
FSS (Full Service Supplier)
FTT (First-Time-Through)
GAGE R&R (Gage Repeatability & Reproducibility)
HIC (High Impact Characteristic)
JIT (Just In Time)
KPIV (Key Process Input Variable)
KPOV (Key Process Output Variable)
LRR (Launch Readiness Review)
MP&L (Material Planning and Logistics)
MS (Material Specifications)
MSA (Measurement Systems Analysis)
NIST (National Institute of Standards and Technology)
np Chart (Chart for monitoring defective-nonconforming individual products)
OEE (Overall Equipment Effectiveness)
PD (Product Development)
PEO (Product Engineering Office)
PFMEA (Process Failure Modes & Effects Analysis)
PMT (Program Module Team)
PPAP (Production Part Approval Process)
Ppk (Performance of process)
PSW (Part Submission Warrant)
PVA (Percent Value Add)
PVT (Plant or Product Vehicle Team)
QOS (Quality Operating System)
QR (Quality Rejects)
RPN (Risk Priority Number)
SC (Significant Characteristic)
SDS (System Design Specification)
SEI (Software Engineering Institute) Date Created: 10/30/02
Originator: Laura Blair Johnson (lblair@ford.com) Page 2 of 31 Pages Date Printed: 11/30/2010
LIST OF ACRONYMS USED IN THE Q1 SITE ASSESSMENT
SFMEA (System Failure Mode and Effects Analysis)
SIM (Supplier Improvement Metrics)
SMED (Single Minute Change of Die)
SPC (Statistical Process Control)
SREA (Supplier Request for Engineering Approval)
STA (Supplier Technical Assistance)
TGW (Things Gone Wrong)
TPM (Total Productive Maintenance)
VDA (Verband der Automobilindustrie - International Standard)
VO (Vehicle Operations)
VOC (Voice of the Customer)
WERS (Worldwide Engineering Release System)
YC (Potential Critical Characteristic)
YRT Rolled Throughput Yield
YS (Potential Significant Characteristic)
Date Created: 10/30/02
Originator: Laura Blair Johnson (lblair@ford.com) Page 3 of 31 Pages Date Printed: 11/30/2010
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION:
8 Green: (0) RED sub-elements and (0) YELLOW sub-elements - All sub-elements are GREEN
9 Yellow: (0) RED sub-elements and (1) or more YELLOW sub-elements
10 Red: (1) or more RED sub-elements
11 INC: (1) or more sub-elements not ranked RED, YELLOW or GREEN
12
13 Expectation Sub-element G/Y/R DEFINITION:
14 G: High Quality of Event / Meets the Expectation and the intent of the Expectation Guidelines / On schedule
15 Y: Marginal Quality of Event / Marginally meets the Expectation and the intent of the Expectation Guidelines / Concurred and timed recovery plan in place
16 R: Unacceptable Quality of Event / Does not meet the Expectation and the intent of the Expectation Guidelines / Inadequate and/or untimed recovery plan in place / Behind schedule
17
18
I. Planning for Manufacturing Process Capability
19
20 INC I.1. Quality procedures/QS-9000/TS16949/QOS
26
27 I.1.1
X Supplier's quality system is third-party certified to the QS-9000 or TS 16949 (full compliance to w Supplier is third party certified to QS 9000 or TS 16949. Include the name of the
28 Rate this TS16949 by December 14, 2006) requirements. registrar organization and the date of certification and/or re-certification.
29 sub- w Certification has not expired.
element by
entering
r, y, or g in
cell above
30
31
32 I.1.2
33 X Existing Supplier's environmental system will be certified to ISO 14001 by July 1, 2003. Non-Q1 w Supplier has a plan to be third party certified to ISO 14001 by July 1, 2003
Rate this suppliers must comply to ISO 14001 requirements prior to Q1 award or Q1 reinstatement. w If supplier is not ISO 14001 compliant, there is an action plan in place regardless of Q1
34
sub- status.
element by Note:
entering Existing Q1 suppliers will be certified to ISO 14001 or provide evidence of "good faith
r, y, or g in effort" by July 1, 2003. Evidence of ISO 14001 good faith effort consists of:
cell above - Registrar letter of recommendation based on successful certification audit
- Registrar phase I or phase II audit results
- Registrars confirmation of phase I audit date
35 - FTDC/AIAG ISO 14001 training registration and registrar contract
36
37 I.1.3
Supplier's quality manual contains processes for all areas of the site assessment. The quality
manual is updated as needed to drive statistically valid continual improvements in the supplier's
quality system. Supplier's Senior Management Team, including representatives from
Manufacturing, Quality, Engineering, and Human Resources perform these reviews. For foundry
material suppliers, if no formal QC manual is available, what documents are used to define
processes which are required to meet customer requirements?
4 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6 I.1.3
7 X Expectation Element G/Y/R DEFINITION: for all areas of the site assessment. The quality
Supplier's quality manual contains processes w Supplier reviews on an annual basis the policies, procedures, and work instructions to
Rate this manual is updated as needed to drive statistically valid continual improvements in the supplier's ensure they are up to date, including Voice of the Customer (VOC) specific
sub- quality system. Supplier's Senior Management Team, including representatives from requirements. This may be included in the annual review of internal audits. Action
element by Manufacturing, Quality, Engineering, and Human Resources perform these reviews. For foundry plans are in place for statistically significant continuous improvements.
38 material suppliers, if no formal QC manual is available, what documents are used to define
entering
r, y, or g in processes which are required to meet customer requirements? w There are records of revisions (change control) to procedures, guidelines and work
cell above instructions that demonstrate that supplier's quality system is being continuously
39 improved.
40
41 I.1.4
42 X Nonconformances identified in internal audits are not repeated. w Supplier has an internal quality audit tracking mechanism in place.
Rate this w Supplier's "quality manual" includes a procedure for internal audits and corrective
43 sub- action implementation process
element by w Supplier has an internal audit schedule and audits are being performed according to
44 entering schedule
45
r, y, or g in w Does supplier use a "fresh eyes" concept?
cell above w Supplier has records of 3 previous audits, including a list of all non-conformities and
46 non-compliances.
w For all non-conformances, action plans are in place to address the root cause that led
47 to the issue.
w Supplier implements corrective actions in related activities to prevent recurrence of
48 similar non-conformances.
49 w Supplier links issues and corrective actions to customer satisfaction (VOC)
50
51 I.1.5
X Supplier has a documented process to identify and regularly update customer expectations, w External Critical to Quality (CTQ) customer expectations are obtained from all affected
Rate this objectives, and requirements. customer activities (i.e., Purchasing, STA, PD, Manufacturing Plants, Finance, MP&L,
52 sub- Materials Engineering, Global Paint Engineering, etc.)
element by wExternal CTQ customer expectations may include metrics (if applicable) such as, QR's,
entering Process Sigma Level, CPU, R/1000, TGW, PPM, warranty, project timing, PSW timing,
r, y, or g in response time on customer complaints, delivery performance, etc.
53 cell above
54
55 I.1.6
X Supplier has a documented process to identify and regularly update internal expectations, wSupplier identifies internal CTQ metrics that are not covered by external metrics.
56 Rate this objectives, and requirements.
sub- wInternal metrics may include (if applicable) internal scrap rates, batch
element by adjustment/reblend rates, OEE, down-time, change-over time, Cpk, DPU, RTY, etc.
entering
r, y, or g in
57
cell above
58
59 I.1.7
X Supplier has a documented process to translate internal and external expectations, objectives, wSupplier's CTQ measurables relate to key process output variables (KPOV) that
Rate this and requirements into QOS measurables. predict internal and external customer satisfaction.
60 sub-
element by wContinuous improvements are developed and tracked through internal and external
entering expectations.
61 r, y, or g in
cell above
5 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
I.1.7
Expectation Guidelines
Due Date
Rating
X Supplier has a documented process to translate internal and external expectations, objectives,
Rate this and requirements into must list evidence to support each Expectation.
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier QOS measurables. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
sub-
element by (*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
entering
6 r, y, or g in
62 cell above Expectation Element G/Y/R DEFINITION:
7
63 I.1.8
64 X Supplier has a documented process to assign targets and objectives to each QOS measurable. wSenior management has communicated clear expectations of the QOS process.
Rate this wThe QOS process includes quantifiable improvements that are significant and
sub- sustainable.
element by
entering
65 r, y, or g in
66 cell above
67 I.1.9
X Supplier has a documented process to assign chosen measurables to appropriate management wA management champion and team is identified for each CTQ measurable, which is
Rate this levels for review, follow-up, and improvements. then tracked and reviewed to ensure improvements are being made.
68 sub-
element by wPerformance of these measurable are communicated regularly.
entering
69 r, y, or g in
70 cell above
71 I.1.10
X Supplier utilizes action plans to drive statistically valid continual improvement of chosen metrics w Action items are being closed on time and show statistically valid improvements.
72 Rate this and are tracked at QOS review meetings.
sub- w These improvements are permanent in nature or are they short term fixes?
73 element by
entering w Is STA invited to supplier's QOS review meetings?
74 r, y, or g in
75 cell above
76 I.1.11
X Supplier's management team holds monthly QOS performance review meetings with w Supplier has evidence of the monthly QOS meetings, including what metrics are being
Rate this representatives from Manufacturing, Quality, Engineering, and Human Resources. Improvement tracked and managed.
sub- actions are taken by cross-functional teams that include all levels of the organization.
element by
entering
r, y, or g in
cell above
77
w Supplier has a strategy implementation process with defined roles and responsibilities,
78 and on-going actions with timing.
w Cross-functional teams have been formed and working meetings are being conducted.
79
w There is evidence of cross-functional team meeting minutes, metrics, and action items
for monthly QOS meetings and daily production meetings with senior plant
80 management.
81 w Supplier is tracking trends to drive continuous improvement.
w Corporate strategy and objectives are linked to assure continuous improvement of
82 metrics.
w Supplier's continuous improvement projects utilize statistical quality tools, including
83 what impact these quality tools have on internal and external CTQ metrics.
6 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
I.1.11
X Supplier's management team holds monthly QOS performance review meetings with Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
FORD PROPRIETARY
Rate this representatives from Manufacturing, Quality, Engineering, and Human Resources. Improvement
6/1/2003
sub- actions are taken by cross-functional teams that include all levels of the organization.
element by
entering
B E F G H I J K L M N
r, y, or g in
1 Date: E-Mail: STA Site Engineer:
cell above
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w Supplier can demonstrate that an effective daily management review process is in
place with cross-functional representation reviewing and reacting to daily production
metrics. The review process includes meeting minutes and/or an action log. If a daily
management review process is not held, what mechanisms are used to review and
84 react to daily production metrics.
w Supplier can identify what quality tools are being used and that improving trends are
85 being tracked.
86
87 I.1.12
X QOS reviews include a review of all applicable Ford SIM metrics, key process metrics, and w Supplier monitors customer plant(s) QR trend and 3MIS warranty R/1000 and CPU
Rate this customer satisfaction metrics. performance, where applicable, to proactively address customer satisfaction concerns.
88 sub-
element by w Customer concerns in SIM and quality rejects show improving trends or are at zero
89 entering level.
90 r, y, or g in w Supplier can access SIM and review QR and Concern details on a daily basis.
91 cell above w Supplier is tracking all Ford SIM metrics.
w Supplier's internal metrics include scrap, downtime, rework, reblends, batch
92 adjustments, and premium freight, etc.
w Supplier can demonstrate that goals have been set for the Ford SIM metrics with
93 action plans in place to drive improvement.
w Supplier tracks warranty, if applicable and/or if warranty data is available, and has an
evaluation process to determine what drives improvement in warranty costs and
94 customer satisfaction.
95
96 I.1.13
X Metrics monitoring customer satisfaction that are related to supplier manufacturing are understood w Supplier assesses how much the TGW, CPU, and R/1000, if available, are related to
97 Rate this and tracked. supplier manufacturing and action plans are developed based on those findings.
sub- w Supplier has a tracking mechanism for short-term and long-term warranty Things-
98 element by Gone-Wrong (TGW), if available.
entering Note:
r, y, or g in Ford's Product Development/Global Paint Engineering/Materials Engineering can provide
99 cell above TGW information for most products.
Note:
100 Short-term is defined as < 12 months; Long-term is defined as > 12 months
w Supplier has a tracking mechanism for long-term and short-term warranty Cost-Per-
101 Unit (CPU) if CPU is available.
102
w Supplier has a tracking mechanism for short-term and long-term warranty R/1000 if
103 R/1000 is available.
104
w As part of its field return parts/product analysis, the supplier includes the number of
105 parts or quantity of product and root cause analysis, where possible
w Supplier has a procedure for short-term and long-term customer satisfaction and is
106 compliant.
Note:
107 Information can be obtained through JD Power or OEM for most products.
108
7 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
X Metrics monitoring customer satisfaction that are related to supplier manufacturing are understood
Rate this and tracked.
sub- FORD PROPRIETARY
Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
element by 6/1/2003
entering
r, y, or g in
B E F G H I J K L M N
cell above
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w Supplier understands and utilizes the High Mileage Reliability process in developing
109 products for Ford when specifically requested to do so.
w Supplier analyzes low- and high-time in service, if available, as part of its continuous
110 improvement project selection process.
111
112
113 INC I.2. FMEAs/Control Plans*
119
120 I.2.1
X All Ford parts/products and families of Ford parts/products (including material defined by a Ford w Supplier has documented process for developing and continuously improving
121 Rate this materials specification, have documented design and process failure mode and effects analysis DFMEAs, PFMEAs, and control plans for all Ford parts/product.
sub- (DFMEA, PFMEA), and Control Plans (or DCPs). There is a robust process in place for w Supplier obtains and reviews, if available, system and design FMEA or Design
element by developing these documents. Verification Plan & Report (DVP&R) from a System and/or Design & Release Engineer
entering to ensure that "effective and credible" PFMEA/Control Plan/work instructions can be
122 r, y, or g in developed and implemented.
cell above w Supplier uses a process flow diagram or surrogate control plan when developing a
123 PFMEA / DFMEA.
w Supplier reviews DFMEAs / PFMEAs, identifies "potential cause of failure," and
124 implements error-proofing, where applicable.
Note: Refer to the FMEA reference manual to ensure that all requirements are met.
125 Website is listed below:
126 https://web.keyinfo.ford.com/northamerica/manuals/html/FMEA_Docs.htm
Note:
If involved in a new program,If the supplier-led APQP team does not have system/design
FMEA and/or DVP&R, then the element in the APQP tracking document "MUST" be
identified as "RED" and all related documents, such as PFMEA/Control plan, should be
127 identified as "Yellow".
128
129 I.2.2
X FMEAs are reviewed annually or as issues arise. A Pareto is used to focus on 1) severity, 2) the w Supplier understands how to develop a robust FMEA (i.e., understands the process
Rate this combination of severity and occurrence, and 3) to identify high RPNs in order to prioritize actions function, failure mode at that function, its effects and causal factors, and detection
130 sub- to drive improvements. methods)
131 element by w Supplier understands how to use the occurrence and detection rating.
132 entering w Supplier reviews performance data to validate the ratings.
r, y, or g in w Supplier understands what quality tools, such as, cause & effect (C&E) diagrams
cell above (based on process dominance such as "set up", "machine", "fixture/pallet", "tooling",
etc.), P-diagram, DOE, Value chain mapping, Design Matrix, etc., were used and how
analytical data was developed and used to develop DFMEA (for Full service Supplier)
133 and PFMEA.
w Supplier has a process to track FMEA revisions. Revision levels are included on
134 FMEAs.
w Does the supplier use the recommended Ford FMEA Manual or the AIAG FMEA
135 Manual?
Note:
Specifying severity and occurrence ratings for SCs is equivalent to establishing RPN
thresholds. Rankings are subjective and therefore cannot often be compared between
136 parts/products. Let the highest severity & criticality drive SC selection.
8 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
I.2.2 6/1/2003
X FMEAs are reviewed annually or as issues arise. A Pareto is used to focus on 1) severity, 2) the
Rate this combination of severity and occurrence, and 3) to identify high RPNs in order to prioritize actions
B E F G H I J K L M N
sub- to drive improvements.
1 element by Date: E-Mail: STA Site Engineer:
2 entering Supplier Name: Phone#: E-Mail:
r, y, or g in
3 cell above
Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: Note: Per the Ford FMEA manual,
> RPN is a value between 1 to 1000. There is no threshold value above which an action
must be taken or below which we are excused from considering an action
> Severity: Rankings of "9" or "10" are restricted to safety or government regulated.
> Occurrence: The criteria for ranking Occurrence "1" is the probability of failure is
remote: failure is unlikely.
> Detection : The criteria for ranking "1" is that detection is almost certain.
137
138
139 I.2.3
140 All error detection areas are reviewed and plans exist to move to error prevention devices, where w Supplier has a process to move from detection to prevention.
141 feasible.
142 w Supplier shows evidence that the error-proofing methods, if used, are effective.
w Supplier understands how to correlate prevention to CC's, SC's and HIC's (where
applicable) to determine effectiveness of the method (i.e., can address the causal factor
143 (failure mode)).
144
145
146
147 I.2.4
148 X Suppliers, in cooperation with its customers, have identified Significant Characteristics (SCs) and w If a supplier is FSS, the YCs are defined on DFMEA
Rate this High Impact Characteristics (HICs) - where applicable on their PFMEAs and Control Plans for Note:
sub- every Ford part/product or family of Ford parts/products. SC's and HIC's are not necessarily restricted to part characteristics. Process parameters
element by are equally critical to the parts characteristics. The process parameters must also be
entering identified as SC's and HIC's and must be monitored and managed through the control
149 r, y, or g in plan.
cell above Note:
Critical Characteristics "CC" or inverted delta can be only identified by Ford's design and
releasing activity and must be identified on the Ford drawing and/or engineering/material
specification. Suppliers, full service or not, cannot identify any characteristics as "CC" on
their DFMEA/PFMEA
150
151
152 I.2.5
X Suppliers works with Ford (i.e., Program Vehicle Teams (PVT), Program Engineering Office w Supplier determines SCs and HICs (where applicable) from the system/design FMEA
Rate this (PEO), Component Review Teams (CRT), Material/Product Engineering, Global Paint with additional characteristics identified by the PFMEA cross-functional team.
153
sub- Engineering, Supplier Technical Assistance (STA)) to establish final agreement of SCs and HICs.
Suppliers obtain specific agreement from Ford for any parts/product not having SCs or HICs. Note:
element by For SCs and HICs (where applicable), severity rankings are between 5-8, with
entering Occurrence rankings between 4-10.The product/process characteristics identified as SC,
r, y, or g in HIC and CC in the PFMEA must also be identified in the control plan/work instructions.
cell above Additionally, rankings for CC (inverted delta) and OS (operator safety) are severity = 9 or
154 10, with Occurrence rankings between 1-10.
155
156 I.2.6
X Supplier ensures that all print dimensions and call-out notes on the engineering drawing, if w For parts, all other dimensions not specified in the control plan have a frequency of
Rate this applicable, and all requirements listed in the material specification or "Sheet 3" for steel are inspection identified in the layout report and in the quality procedure manual. (Annual
157 sub- always met through control plans, work instructions, job/equipment set-up instructions, and lay-out can be considered)
element by receiving inspection.
entering
r, y, or g in
cell above
9 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
I.2.6
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
X (*Denotes Focus Area)
Supplier ensures that all print dimensions and call-out notes on the engineering drawing, if inclusive. Refer to the AIAG Manuals to ensure compliance.
Rate this applicable, and all requirements listed in the material specification or "Sheet 3" for steel are
6 sub- always met through control plans, work instructions, job/equipment set-up instructions, and
7 element by receiving inspection. G/Y/R DEFINITION:
Expectation Element w All process or product characteristics being used to manage the manufacturing
158 entering process are identified on the control plan
r, y, or g in w There is evidence that full dimensional validation (lay-outs) are completed annually for
cell above parts. For product, there is evidence that all material specification requirements are
validated at least annualy or as specified on the customer approved control plan.
Note: Actual measurement and/or test results are available.
159
w There is operator-based, statistical process control evidence that supports sample
frequency for all print dimensions whether or not they are identified on the control plan.
160
w Process parameters that affect the Critical to Quality characteristics of the part/product
161 are identified and controlled.
w Supplier is compliant to Vehicle Parts Branding Directive E-108 for any new product
162 after 8/1/2002.
Note:
E-108 Parts Branding Directive can be found on the Ford Supplier Network (FSN) at:
163 https://web.purinfo.ford.com
164
165 I.2.7
X Supplier verifies pass-through characteristics, if any, and ensures that zero defects are at Vehicle w Supplier has specific controls in place that are robust in preventing and containing non-
166 Rate this Operations (VO) and final customer. conformances.
sub- w Pass-through characteristics, if present, have been identified for all new parts and
element by existing parts/product. These pass-through characteristics are identified on the PFMEA
entering and control plan. (The intent is to implement robust controls within the process control
r, y, or g in plans / work instructions to manage pass-through characteristics.)
167 cell above
w Supplier has a process for identifying and managing pass-through characteristics with
sub-suppliers if the product is not monitored thru 100% incoming batch testing and/or
review of Certificates of Analyses.. This process includes obtaining data from sub-
suppliers to ensure that pass-through characteristics are monitored and compliant.
168
w Pass-through characteristics are evaluated jointly between Ford's manufacturing
engineering, product/materials engineer, STA, and the supplier during the development
of PFMEA/Control Plan. (The intent of this process is to identify those characteristics
that could have significant impact on customer satisfaction and warranty and may not
169 have been identified as SCs, CCs.)
w Supplier reviews error-proofing methods for all pass-through characteristics. Action
170 plans are in place to implement error-proofing methods, where required.
Note:
Pass-Through Characteristics (PTC) are defined as: Product Characteristics that are
supplied to receiving Ford Plants by an outside supplier or by an internal (Ford) supplier
that are not controlled by subsequent processing of the using plant. Defective PTCs may
171 affect Vehicle Operations or the buying public.
172
173 I.2.8
Control Plan is a result of appropriate quality planning and includes clear linkage between DFMEA
and PFMEA.
10 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6 I.2.8
7 X Control Plan Element of appropriate quality
Expectation is a result G/Y/R DEFINITION: planning and includes clear linkage between DFMEA w Supplier can demonstrate linkage between DFMEA, PFMEA, Control Plan, Work
Rate this and PFMEA. Instructions, etc.
sub-
element by
entering
174 r, y, or g in
175 cell above
176 I.2.9
177 X Control Plans contain the following elements: w Control Plans / Work Instructions are readily available.
Rate this Note :
sub- Additional information on Control Plans can be found in the AIAG Advanced Product
element by Quality Planning and Control Plan Reference manual
entering http://www.ctis.ford.com/fao_qualstandard/secure1/data/3223691.pdf
178 r, y, or g in
-- Operation number / name
179 cell above
-- Part Name / Part Number / Material Specification Number. w Control plans identify the latest part level (suffix) or material specification
180
-- Inspection Requirements
181
-- Specifications w Product and process CTQ specifications are included in the control plan
182
-- Control Methods w Control methods are specified in the PFMEA/control plan/work instructions and are
183 appropriate for the type of process.
184 w Work instructions clearly define quality acceptance criteria
Note:
Operations may be controlled by, but not limited to, Statistical Process Control,
inspection, attribute data, error-proofing (automated or non-automated), sampling plans,
visual aids, operator instructions, SPC charting, gaging, auto-compensators, process
modelling, feed-forward/feedback control, lab testing, in-line measurement/testing, batch
185 sheets, etc.
-- SC, CC, HIC (where applicable), and Engineering Specifications (ES) w A cross-functional team is formed (including customer) to identify SCs, CCs, HICs
186 requirements (where applicable) are identified and appropriate (where applicable), and ES
w For new programs, SC, CC, HIC (where applicable) and ES control methods are
consensed by the Component Review Team (CRT) (CCs are established by Ford only)
187
w All CCs, SCs, and HICs (where applicable) from the PFMEA have been identified on
188 control plans.
189 w Engineering Specifications (ES) are identified by ES No. on control plans.
-- SC, CC, HIC (where applicable), and ES Control methods (if applicable) are appropriate. w Variable data is being collected by the equipment operators or by automatic data
190 entry, where appropriate.
w Listed process parameters and part/product characteristics are being controlled using
191 the method identified in the control plan/work instructions.
w Gaging method, if applicable, is appropriate for the task and was specified during the
192 APQP process.
-- Error proofing methods w Error proofing methods that are in place cannot be circumvented by the operator and
193 are on the plant's certification program.
194 w Operator understands the reason for the error proofing method.
195 w Error-proofing methods are tested for effectiveness.
11 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must
-- Error proofing methods list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w If applicable, Process maps, Kaizan documents, include (1) Load Balancing, (2) Poke
Yoke, (3) Pull/Flow Systems, (4) Small Batch Sizes, (5) Event Minutes, (6) Kaizan
196 Process Documents, (7) Kaizan Schedules, (8) Kaizan Resources.
-- In-process control methods w Control methods (i.e., in-process testing, 100% inspection, SPC, visual inspection,
etc.) are identified on the control plan as specified in the PFMEA and included in the
operator's standard of work. Control methods are modified as required.
197
-- Sample Size and frequency w Sampling plans, if used, are statistically valid (based on quantity and variation) and
justify probability of occurrence for a given cause or failure mode.
198
-- Required measurement and test equipment w Required test and measurement equipment and, if applicable, tools and gages, and
199 are identified for sub-suppliers.
-- Reaction plans must clearly direct the operator on how to act when a process begins to go out w Reaction strategies (i.e. part/product containment, supervisor notification, line shut-
200 of control, or a product fails an inspection or test. down, etc.) are specified for out of control conditions if SPC Control Charts are used.
201 w Operator(s) understand the conditions for an "Out of Control" state.
w Reaction plans are adhered to (i.e. can provide when, why and what was done when
202 an operation went down thru downtime sheets, end of line metrics, etc.)
w Roles and responsibilities for all production and production support personnel are in
place to support direct labor personnel, and have specific responsibilities to react to out-
203 of-standard conditions.
204
205
206 INC I.3. Employee Readiness/Training Review
212
213 I.3.1
X Supplier is responsible for assessing the skills required to perform all activities that affect product w Supplier has a selection criteria process to assign skilled operators to a given
214 Rate this quality. function.
215 sub- w There is evidence of skills management procedure.
216 element by w Supplier manages its training to compensate for turnover rate.
entering w There is a process to manage absenteeism, especially for a given critical
217 r, y, or g in manufacturing process (which is based on severity and occurrence).
cell above w Supplier identifies operator skill set and training requirements.
218
w As part of the APQP process, if involved in a new Ford program, employee staffing,
skill requirements, and training are identified, and support program timing.
219
220
221 I.3.2
222 X Employees have a skills assessment, training plan, and evidence of training. w Supplier has a training program and can demonstrate compliance to training plans.
223 Rate this w Training is part of the supplier corporate objectives
sub- w There is a process to determine training needs. "On the Job" training recorded
224 element by and managed
225 entering w There is a planned training program for each employee (hourly and salary).
226
r, y, or g in w There is a process in place to address a high turnover rate condition
cell above w Operator qualifications/training records are readily available to the production
227 supervisor
12 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
I.3.2
X Employees have a skills assessment, training plan, and evidence of training.
Expectation
Completion Date
Responsibility
Expectation &
Rate this
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
sub-
Rating
element by All Expectations, regardless of Color Rating, shall have documented Action Plan
entering Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
r, y, or g in (*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
cell above
6
7 Expectation Element G/Y/R DEFINITION: w Training records of key salaried personnel (i.e., QC manager, Incoming Receiving
228 managers, etc.) are reviewed regularly for compliance.
229
230 I.3.3
X Supplier ensures that only trained and qualified personnel are involved in all aspects of the w Operators understand the application of the component/product they are producing.
231 Rate this manufacturing of Ford Parts/Product.
sub- w Operators understand what is critical in the component/product and what could
232 element by happen (consequence of failure mode) if it does not meet specification
233
entering w Operators are/were part of work instruction development process
r, y, or g in
234 w Operators are/were trained prior to performing the job
cell above
w There is a defined process where operators have the opportunity to provide feedback
235 (related to the process and/or job) to their supervisor/manager.
236
237
238 INC I.4. APQP/Launch/PPAP/Run-at-Rate Review
245
246 I.4.1
X Supplier has a APQP tracking mechanism in place for product being made for a new Ford w Supplier management reviews, at a minimum, the Ford APQP manufacturing
Rate this program. Otherwise, the supplier utilizes APQP concepts for new product not associated with a elements to ensure proper tracking, documentation, and action plans for any applicable
247 sub- new program launch. new program.
element by w All new Ford programs are being tracked according to the Ford APQP Reporting
248 entering Guidelines.
r, y, or g in w Action plans are developed to improve any yellow or red APQP elements.
249
cell above
Note: Refer to the APQP reference manual to ensure that all requirements are met:
250
251 http://www.ctis.ford.com/fao_qualstandard/secure1/fao_qualstandard_toc_flat.html
252
253 I.4.2
X Supplier has a system to manage new vehicle program launches (if involved in new model w Supplier's Program Management Team is separate from the Product Development
254 Rate this programs). team, and both are accountable to senior management.
sub- w Supplier's Program Management Team has dedicated resources to support the
255 element by program, including key sub-suppliers.
entering w Program Management Team includes personnel from the supplier's manufacturing
256 r, y, or g in plant.
cell above w Supplier's new programs are tracked and monitored based off of Ford's PD
257 milestones.
w Supplier has the required CAD/CAM systems (applicable to parts only) to interface
with Ford, and that capability is at the supplier's manufacturing site, where possible.
258
w Supplier's PD system is a formalized process that prevents verbal-only design
259 direction.
w Supplier has a process to keep Ford informed of program status and/or issues.
260
w Supplier is active on the PMT's and participates in all program reviews involving the
261 supplier.
w Milestone reviews are scheduled and conducted to communicate launch status, open
262 issues, and issue closure status to supplier's senior management.
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
I.4.2 6/1/2003
X Supplier has a system to manage new vehicle program launches (if involved in new model
Rate this programs).
B E F G H I J K L M N
sub-
1 element by Date: E-Mail: STA Site Engineer:
entering Supplier Name: Phone#: E-Mail:
2
r, y, or g in
3 cell above Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w There is a defined plan to communicate program status to supplier's manufacturing
263 plant.
w Supplier understands its FSS deliverables and has a system in place to execute them.
264
w Supplier uses Robust Design Principles and customer-approved Design/Testing Lab.
265
266 w Supplier uses a LRR process to track and assess its sub-suppliers.
267
268 I.4.3
X Supplier has a process in place to support Ford prototype and pre-production build events in a w Supplier develops pre-production and prototype parts/product that simulate its
269 Rate this timely manner (if involved in new model prgrams). production process.
sub- w Supplier verifies that all prototype parts/product meet engineering, dimensional,
270 element by material, and functional requirements.
271 entering w Supplier requires, if applicable, and utilizes Prototype Control Plans.
272 r, y, or g in w Supplier reviews and signs off sub-supplier inspection results prior to CP Build.
cell above w Supplier has dedicated resources to support all prototype builds on site at Ford, and
273 an agreed structure for managing issues.
w Supplier understands the RED Border Process and is operating within the guidelines
274
w Supplier supports all vehicle walk-around, AIMS, shortage, and change control
275 meetings.
w Supplier has dedicated Ford Assembly Plant and Vehicle Engineering resources
276 available to support launch.
w Supplier launch support personnel are technically capable to work on any launch
277 issue.
w Supplier on-site launch support personnel provide timely responses to all launch-
278 related issues or requirements.
w Supplier launch representatives are empowered to take immediate action on issues
279 requiring fast turn-around by the launch team.
280 w Supplier launch representatives are available for around-the-clock access.
w Supplier addresses launch readiness issues with Ford by defining an owner and action
within 24 hours, and drives closure of the issues in an agreed-upon timely manner.
281
282
283 I.4.4
284 X Supplier has a process to continuously monitor and improve launch performance (if involved in w Supplier has a system that tracks performance to meet PSW dates.
285 Rate this new model program launches). w Supplier manages sub-suppliers to assure PSW timing is met.
sub- w Supplier has a process to notify its customers, including buyers, of any slips to PSW
286 element by timing.
entering w Supplier has a system in place that responds to all Ford Consumer Product Audit
287 r, y, or g in (FCPA) issues, where applicable.
cell above w Supplier has a process to contain and resolve all FCPA issues prior to the next build.
288
289 w Supplier validates all FCPA fixes with the customer prior closing any AIMS issue.
w Supplier has a formal system to conduct operator-based Quality Stand Downs on all
290 new product or process launches.
291 w Supplier drives the operator-based Quality Stand Down process to its supply base.
14 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code:
I.4.4 If Supplier Self-Assessment, Approved By: Material name/specification number
4 X Supplier has a process to continuously monitor and improve launch performance (if involved in
Supplier Contact: Name:
Rate this new model program launches).
5 sub-
Phone#:
element by
entering
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
r, y, or g in
Expectation Guidelines
Due Date
cell above
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w Supplier incorporates Quality Stand Down information into the PFMEAS and Control
292 Plans.
w Supplier has a process to conduct Fresh Eye Reviews on all new products, gages,
processes, and equipment, and utilizes its personnel from sister plants, divisional and
293 corporate staff, and/or customers.
w Fresh Eye Review findings are documented by the supplier, and action plans are
294 developed for all areas requiring improvement.
w Supplier has extraordinary launch plans in place to ensure a safe launch of its new
295 product.
296 w Supplier utilizes inspection data to validate extraordinary launch plans.
w Supplier has a process to move out of extraordinary containment plans only when
specific quality levels are met (e.g., , for parts production if applicable, 3000 consecutive
297 parts with ZERO defects found).
298
299 I.4.5
300 X All PPAP documentation must contain the information per the PPAP manual published by the w Supplier is compliant to PPAP (AIAG) procedures
Rate this Automotive Industry Action Group (AIAG) - this information must also be available for Ford review. Note: Refer to the PPAP reference manual to ensure that all requirements are met:
301 sub- Bulk material suppliers should use the Bulk Materials Requirement Checklist found in the AIAG
302 element by
PPAP manual. Suppliers in North America have a process in place to comply with Phased http://www.ctis.ford.com/fao_qualstandard/secure1/data/3225266.pdf
entering PPAP initial run-at-rate, production verification and capacity verification if requested to do so. w PPAP documentation must be no more than one year old at the time of initial PSW
r, y, or g in submission. Ford Powertrain plants require a copy of the PSW when parts/products are
303 cell above shipped.
w All PPAP submissions on record are to the latest Ford current design released print or
material specification. (FSS suppliers submit their designs/formulations to Ford for Ford
304 release.)
305 w Supplier has a process for tracking "PPAPs with alert"
w If an alert is required, supplier includes the alert number and description on the PSW
under "Declaration -- EXPLANATION/COMMENTS." (Under "Submission Results", the
306 box must be checked "NO")
w On PSWs with "alerts", the supplier has submitted a PPAP for these parts/products
prior to expiration of the alert (alerts are normally for 90 days only).
Note:
If the supplier has not submitted a PPAP for parts/products after the alerts have expired,
the supplier is not compliant and the buyer, product /materials engineer and the STA
Resident must be notified.
307
15 of 31 Date Created: 4/4/03
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I.4.5
X All PPAP documentation must contain the information per the PPAP manual published by the
Rate this Automotive Industry Action Group (AIAG) - this information must also be available for Ford review.
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
sub- Bulk material suppliers should use the Bulk Materials Requirement Checklist found in the AIAG 6/1/2003
element by PPAP manual. Suppliers in North America have a process in place to comply with Phased
entering PPAP initial run-at-rate, production verification and capacity verification if requested to do so.
B
r, y, or g in E F G H I J K L M N
1 cell above Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w Substance use restrictions conform with the Ford environmental specification WSS-
M99P9999-A1 and is included in the PPAP submission under Appendix D, Production
Part Approval - Material Test Results
Note:
Refer to FSN / FSP, Environmental for the WSS-M99P9999-A1 standard, and review
supplier evidence of material reporting. Rust inhibitors and other chemicals that may be
put on the component for part protection and/or for manufacturing may require approval
from Ford Toxicology department. Review if approvals were required and obtained for
any of the parts produced.
308
309
310 I.4.6
311 X Suppliers require sub-suppliers to have a process in place that effectively satisfies all PPAP w Supplier has a production part approval process for it's sub-suppliers.
Rate this requirements regardless of sub-supplier business relationship with Ford. w This procedure requires the supplier to conduct fit and functional approval on their sub-
sub- suppliers prior to PPAP submission to Ford
element by
312 entering
r, y, or g in
313 cell above
314 I.4.7
X Run-at-Rate must be completed and supports the stated program requirements (at full-volume w Supplier submits capacity verification documentation and is in compliance to all newly
315 Rate this production levels) for all Ford parts/product. launched or added capacity parts/product.
sub- Note:
element by Confirm CPV with buyer, if unknown
entering
316 r, y, or g in
317 cell above
318 I.4.8
X Run-at Rate must include the following elements and be performed on the entire process or the w Supplier complies with Ford's documented capacity verification procedure, referenced
Rate this slowest operation (process bottleneck): equipment available hours, shifts, days, equipment in FSN. (Run-at-Rate is part of the overall Capacity Verification Process.)
319 sub- downtime (planned and unplanned), equipment change over, breaks, and quality or scrap.
element by w Supplier's supporting documents demonstrate compliance to all newly launched or
320 entering increased capacity parts/product.
r, y, or g in w Supplier provides timing on all newly launched or increased capacity parts/product
cell above (i.e., Gantt charts)
321
322
323 I.4.9
324 X Supplier monitors capacity and has a process to ensure on-going sufficient capacity on all Ford w Supplier is compliant to Ford's product releases.
325 Rate this parts/product. w Staffing support for Capacity Planning Volumes takes into account turnover rate and
sub- w Supplier has
absenteeism. a process to communicate Ford production requirements to sub-
element by suppliers, and monitors and measures its ongoing effectiveness to ensure 100%
326 entering delivery of sub-supplier components or material to meet supplier/Ford demand.
r, y, or g in w Supplier has a plan to support capacity requirements in case of production
cell above interruptions due to equipment failure and/or sub-supplier performance issues.
327
328
329
16 of 31 Date Created: 4/4/03
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f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION:
330 INC I.5. Manage the Change
337
338 I.5.1
X Supplier has a documented process to effectively implement post - Job 1 design/specification w Supplier has a documented manage the change procedure.
Rate this changes, process changes, or volume changes.
339 sub-
element by w Supplier can validate the procedure with a current example of a change.
entering
r, y, or g in
cell above
340
341
342 I.5.2
X Supplier effectively reviews and updates its quality supporting documentation for these changes. w Supplier has a process to implement internal and external suppliers' (tier 2 or tier 3,
343 Rate this Examples of documents that may require changes: Process Flow Diagrams, FMEAs, Control etc.) proposed changes, which may or may not involve Ford.
sub- Plans, Operator Instructions, Visual Aids, and PPAP documentation. w Supplier identifies new CTQ metrics associated with the change and implements valid
element by measurement system(s) to track key measurables associated with the process change.
344 entering
345 r, y, or g in w Supplier can demonstrate effective communication to Ford of a change.
cell above w Supplier can validate the process using the most recent change, either initiated
internally or by sub-suppliers.
346
347
348 I.5.3
X Supplier follows a documented process to ensure that proper Ford approvals are gained prior to w Supplier reviews each and every change and determines whether that change
349 Rate this making process changes. The approval process will include use of Supplier Request for requires customer approval.
sub- Engineering Approvals (SREAs), Change Request/Concern Report (CR/CR) in Worldwide Note:
element by Engineering Release System (WERS), Management Alerts, and revised PPAP documentation, as Refer to the manage the change procedure in the PPAP manual . SREA procedure is
entering appropriate. available on FSN.
350 r, y, or g in
351 cell above
352
NOTE: Manufacturing Process
Questionnaires are available under the Mfg
Process Checklist tab of this file for the
following processes: Heat Treat,
Electroplating, Fasteners, Casting, Stamping,
II. Demonstration of Manufacturing Process Capability Welding, Plastics Molding, and Machining.
The purpose of these questionnaires is to
provide assistance in evaluating Q1 Site
Assessments for these processes, which
include sub-suppliers, where applicable.
353
17 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
354
7 Expectation Element G/Y/R DEFINITION:
355 INC II.1. Sub-supplier Quality Management *
362
363 II.1.1
X Supplier has a defined process for managing its supply base including identification of those with w Supplier has a defined process for managing its supply base, including resources
364 Rate this high impact to quality. to work with sub-suppliers.
sub- w Supplier has a process of identifying sub-suppliers with a high impact on quality
365 element by
entering w Supplier has a means of communication to notify high impact sub-suppliers of their
366 r, y, or g in status (i.e., e-mail, letter, meeting minutes, database systems, etc.).
cell above w Supplier has a plan in place to develop value stream maps of their tier 1 and 2
367 suppliers where appropriate
Note:
Communication includes FMEAs, control plans, pass-through characteristics, and
368 PPAPs.
369
370 II.1.2
X Supplier requires high impact sub-suppliers to have a quality operating system that is similar to w High Impact sub-supplier compliance to QS 9000 or TS 16949 is demonstrated
371 Rate this QS-9000, TS 16949, or VDA. Supplier verifies sub-supplier compliance by annual on-site through self-assessment or third party registration.
sub- assessment of high impact sub-supplier facilities. w Supplier visits high impact sub-suppliers on a predetermined frequency and conducts
372 element by on-site assessments.
entering w Supplier has documented evidence of these high impact sub-supplier assessments
373 r, y, or g in
374 cell above
375 II.1.3
X Supplier requires PPAP for all parts/product from sub-suppliers, excluding off-the-shelf w Supplier ensures that all sub-supplier PPAP requirements are met, including fit, if
Rate this commodoties (regardless of sub-supplier business relationship with Ford). The Bulk Material applicable and part/product functional approval prior to getting PPAP approval from
sub- Requirements Checklist found in the PPAP manual should be used where applicable. For off-the- ford.
element by shelf commodities (e.g. toluene, natural rubber, carbon black, foundry sand, etc.), the PPAP
entering requirement is per the supplier's discretion.
r, y, or g in
cell above
376
w All sub-supplier parts/products have PPAP documentation. (For off the shelf
commodity material, certificates of analysis or 100% incoming material batch testing are
377 acceptable).
378 w Supplier updates PPAP for any change in production part/product or process.
w When the supplier submits PPAP documentation to Ford, it contains sub-suppliers'
379 PPAP information and/or it is available for review.
w When a PPAP is submitted to Ford, all sub-supplier PPAPs are updated if the original
380 PPAP documentation is more than one year old.
w Supplier requires annual dimensional validation of all parts from sub-suppliers and an
annual material specification requirement validation per the agreed upon control plan for
all material from sub-suppliers (regardless of sub-supplier business relationship with
381 Ford).
Note:
382 It is recommended that sub-supplier PPAPs comply with the AIAG manual
18 of 31 Date Created: 4/4/03
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X Supplier requires PPAP for all parts/product from sub-suppliers, excluding off-the-shelf
Rate this commodoties (regardless of sub-supplier business relationship with Ford). The Bulk Material
sub- FORD PROPRIETARYin the PPAP manual should be used where applicable. For off-the-
Requirements Checklist found Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
element by shelf commodities (e.g. toluene, natural rubber, carbon black, foundry sand, etc.), the PPAP 6/1/2003
entering requirement is per the supplier's discretion.
r, y, or g in
B
cell above E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7
383 Expectation Element G/Y/R DEFINITION:
384 II.1.4
X Where Ford has defined an Engineering Specification (ES), Material Specification, or special w Supplier has documented records of sub-suppliers' compliance to engineering
Rate this characteristics that are the responsibility of the sub-supplier, the sub-supplier must show specifications, material specifications, or special characteristics
sub- compliance to the ES, material specification, or special characteristics in its PPAP submission to
element by the Tier one supplier.
entering
r, y, or g in
cell above
385
386
387 II.1.5
X Supplier requires sub-suppliers to take specific actions to ensure that all pass-through w Supplier has a process to identify and handle sub-supplier pass-through
388 Rate this characteristics, if applicable, are to customer specifications. characteristics, utilizing error-proofing methods and/or 100% material batch testing.
sub- w Robust controls are implemented within the process control plans / work instructions
389 element by to manage pass-through characteristics.
entering w Supplier can demonstrate that pass-through characteristics are analyzed on all new
390
r, y, or g in parts/product and planned for current parts/product.
cell above w All pass-through characteristics are identified on the sub-supplier's PFMEA and
control plan/work instructions, and integrated into the supplier's PFMEA and control
391 plan.
392
393 II.1.6
X Supplier must confirm sub-supplier compliance by review and approval of sub-supplier PPAP w Supplier has a process to approve PPAP'd parts/product before they are incorporated
394 Rate this submission, if applicable, or review and approval of Certificate of Analysis data and/or batch into the process.
sub- inspection test results prior to incorporation of product into supplier manufacturing process. w Supplier has a sub-supplier functional approval process for machining, raw materials,
element by sub-assemblies, heat treat, plating, etc.
entering
395 r, y, or g in
396 cell above
397 II.1.7
X Supplier conducts systemic reviews with sub-suppliers and assures implementation of corrective w Supplier has a procedure in place that defines how to manage sub-suppliers'
Rate this actions across sub-supplier facilities for all issues resulting in stop ship or field action. generated defects (e.g., 8D review process), including permanent corrective action
398 sub- verification process
element by w Sub-suppliers have a documented problem solving methodology.
399
entering
w Supplier has a procedure in place to conduct random incoming quality audits and/or
r, y, or g in
material testing to verify effectiveness of the corrective actions implemented by a sub-
cell above
400 supplier.
401
402
403 INC II.2. Control of Incoming Quality
410
411 II.2.1
412 X Supplier has a strategy for receiving inspection. w Supplier's special characteristics are identified for incoming inspection
Rate this
sub-
element by
entering
r, y, or g in
cell above
19 of 31 Date Created: 4/4/03
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f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
II.2.1
6 X Supplier has a strategy for receiving inspection.
7 Rate this Expectation Element G/Y/R DEFINITION: w The type and frequency of inspection is more stringent on high risk sub-suppliers
sub-
element by
entering
413 r, y, or g in
cell above
414
415 II.2.2
416 X Incoming quality requirements are part of a control plan. If incoming quality inspections are made, w Incoming quality is defined on control plans
417 Rate this there is evidence of the specification and compliance to the specification. If no incoming w If incoming inspections are made, supplier shows compliance to the specifications
418 sub- inspections are made, there is a rationale for qualifying sub-suppliers. w Supplier has supporting rationale if no incoming inspections are made.
element by w Supplier has an operator-based SPC control plan in place, where applicable.
entering
419
r, y, or g in
420 cell above
421 II.2.3
X Incoming Quality Operator follows a reaction plan if raw material or purchased part is found to be w Supplier has a containment policy for incoming quality (i.e., tagging, identifying type of
422 Rate this out of specification. defect, log of defects, 8D review process).
423 sub- w Supplier has a resolution process for incoming inspection rejects.
element by w Supplier assigns responsibility for resolution, progress is being tracked, and sufficient
entering time is allocated to implement permanent corrective action.
424 r, y, or g in
425 cell above
426 II.2.4
427 X Supplier has appropriate resources to manage sub-supplier quality including on-site assessment w Supplier has a process to review sub-supplier quality systems.
Rate this of high impact sub-supplier facilities. w When non-conformities are present, supplier and sub-supplier have specific reaction
sub- plans
element by
entering
428 r, y, or g in
429 cell above
430
431 INC II.3 Control Plans / Operator Instructions*
438
439 II.3.1
X Standardized operator instructions (including control plans, work instructions, batch sheets, job w Work instructions have all of the necessary details, including quality acceptance
Rate this aids, check sheets, equipment/job set-up instructions, and illustrations) are developed and criteria, process and product control parameters, reference to product drawing release
sub- available for operators. level and date and/or current material specification, specific/special gages, tools, test
element by methods, and test equipment required, reaction plan for process and product non-
entering compliance, point of contact, etc.
r, y, or g in
cell above
440
441 w Supplier can demonstrate operator compliance to the work instructions.
442
443 II.3.2
Standardized operator instructions are legible, specific, and controlled. The instructions are
available in the area where the work is being performed (or for capital intensive processes - where
the processes are being controlled) and are followed by operators as written.
20 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6 II.3.2
7 X Standardized operator instructions are legible,
Expectation Element G/Y/R DEFINITION: specific, and controlled. The instructions are w Supplier can demonstrate that operators are adequately trained and supervised in
Rate this available in the area where the work is being performed (or for capital intensive processes - where correctly carrying out their process function in line with the available documented
sub- the processes are being controlled) and are followed by operators as written. instructions, including the correct disposition of set-up and scrap parts/product.
element by
entering
r, y, or g in
cell above
444
w Wherever possible, visual aids are employed at the work station and/or test labs to
445 define and focus on compliance/non-compliance.
w If there is a multi-lingual workforce, supplier can demonstrate work instructions are
446 understood.
447
448 II.3.3
X Reaction plans are clearly defined and protect Ford from non-conforming materials. w Operators understand the consequences of non-compliant parts/product and
Rate this subsequent failure reaching the customer (i.e., downstream operation or to the end
449 sub- customer).
element by w Supplier has a process of notifying customers if non-conforming product has left the
450 entering supplier's facility.
r, y, or g in w Supplier has a containment process if non-compliant parts/product reach the
451 cell above customer.
w Work instructions specify a reaction plan if suspect or non-compliant parts/product get
452 through the system.
w This procedure and/or reaction plan instructs the operator or quality activity on what to
453 do next.
454
455 II.3.4
X Control Plans are revised and updated when products or processes differ from those in current w Control plans are accurate and up to date with latest product specification/drawing and
Rate this production. process revisions.
sub-
element by
entering
456
r, y, or g in
457 cell above
458
For more information, refer to the AIAG Production Part Approval Process (PPAP)
459 INC II.4 Process Variability Monitoring/Reduction* manual or the Statistical Process Control Manual (SPC) .
466
467 II.4.1
X Supplier has determined appropriate statistical techniques and/or the appropriate in-process w Supplier utilizes statistical methods consisting of SPC control charts and/or
Rate this testing/analysis. A key aspect of defect prevention is process variability reduction and the use of Multivariate Data Analysis where applicable.
sub- statistical methods to indicate when action is necessary , and conversely, when processes should
element by be left alone.
entering
r, y, or g in
cell above
468
21 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
II.4.1
X Supplier has determined appropriate statistical techniques and/or the appropriate in-process
Expectation
Completion Date
Rate this testing/analysis. A key aspect of defect prevention is process variability reduction and the use of
Responsibility
Expectation &
Comments / Evidence
Sub-element
sub- statistical methods to indicate when action is necessary , and conversely, when processes should
Expectation Guidelines
Due Date
Rating
element by
entering
be left alone.
All Expectations, regardless of Color Rating, shall have documented Action Plan
r, y, or g in
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
cell above (*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w These methods of control are appropriate for the given process or product
characteristics (i.e., X bar - R chart, Individual Moving Range chart, np charts, median
469 charts, multivariate data analysis, 100% batch inspection/testing, etc. --).
w The process is equipped with process controls, in-line testing/analyzing/measurement,
470 etc
471 w Supplier reviews data and makes appropriate improvements to the process.
472
473 II.4.2
X SPC control charts and/or multivariate data analysis methods and/or in-process 100% batch w Control charts and/or multivariate data analysis, if used, are being utilized to drive
474 Rate this inspection/testing are each optimized for statistically valid sample frequency, sample size, and changes within the process
475 sub- appropriate chart type (if charting is applicable). If charting is done, SPC checks are performed on w In process test/inspection data, if available, is analyzed for trends.
476 element by
a timely basis and out-of-control conditions prompt corrective action as appropriate.
entering II.4.3
477
478 X Process data is maintained, monitored and analyzed by means of control charts and/or
Rate this multivariate methods and/or test data trend charts to drive process and product improvements by w Control charts, if used, capture when a change has been made and that the process
sub- reducing process variability. Evidence of process improvements include: reductions in scrap, has been effectively improved by statistically different before and after data.
479
element by reductions in rework/repair/reblend; increases in first-time through capabilities, Cpk (where
w Control charts, if used, are monitored for out of control conditions.
entering applicable), Process Sigma (standard deviation) level, records of error proofing mechanism
480
r, y, or g in implementation, improvements in material consistency, and reductions in machine/production
w If control charts are used, the cause for an out of control condition is identified and
cell above equipment downtime.
481 recorded, including any action to remedy condition.
w Control charts and/or multivariate analysis charts, if used, are reviewed for out-of-
control conditions and corresponding reaction plans are sufficient.
482
w Any new causes identified by process data analysis and/or control charts are
communicated through the appropriate channels, to the process owner to ensure that
483 FMEAs/Control plan/work instructions, etc. are updated.
484
485 II.4.4
X If SPC control charts are used and show stability and control, then Ppk and Cpk levels are greater w Supplier has a Ppk/Cpk tracking mechanism in place, if Ppk/Cpk indices are
486 Rate this than or equal to 1.67 and 1.33 respectively, for all SCs, CCs, and HICs (where applicable). For applicable.
sub- all SCs and CCs, Cpk trends are tracked over time, and action plans have been put in place to w Where the supplier has reduced the frequency of SPC control charting, if control
element by increase these Cpk values by a process of continuously reducing the causes of variability. These charting could be applicable, there is statistical evidence to support this reduction and/or
entering trends are part of the Supplier's Management routine review. Alternatively, 100% in process some other method of control is in place. (i.e., they become part of a preventive
r, y, or g in material batch testing shows all product specifications, as shown in the customer approved maintenance program, test equipment management program, tool management
cell above control plan, are met. If multivariate analysis methods are used, charts show the product program, die maintenance / replacement program, equipment vibration analysis
487 variables are in control. program, etc.).
w For processes that do not utilize 100% material batch testing, supplier has a method of
analyzing and managing statistically generated data (SPC charts, multivariate analysis
charts) on the manufacturing process(es) that produce Ford parts/product i.e. Six
488 Sigma.
w Cpk and/or multivariate analysis data, if applicable, is used to drive process
489 enhancements that have an impact on product CTQ characteristics.
w If supplier is not statistically monitoring process/product, and is not using 100% batch
490 testing, how is capability ensured?
w For all Ford design identified characteristics (SCs, CCs), if applicable, Ppk (if
appropriate) is > to 1.67 and Cpk, if appropriate, is > 1.33. (Cpk of 1.33 is approximately
491 a 4 Sigma process)
22 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
II.4.4 6/1/2003
X If SPC control charts are used and show stability and control, then Ppk and Cpk levels are greater
Rate this than or equal to 1.67 and 1.33 respectively, for all SCs, CCs, and HICs (where applicable). For
B
sub- all SCs and CCs, Cpk trends are tracked over time, andFaction plans have been put in place to
E G H I J K L M N
1 Date:
element by increase these Cpk values by a process of continuously reducing the causes of variability. These E-Mail: STA Site Engineer:
entering trends are part of the Supplier's Management routine review. Alternatively, 100% in process
2 Supplier Name: Phone#: E-Mail:
r, y, or g in material batch testing shows all product specifications, as shown in the customer approved
3 Supplier Site Code:
cell above control plan, are met. If multivariate analysis methods are used, charts show the product If Supplier Self-Assessment, Approved By: Material name/specification number
4
variables are in control.
Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w If variable sampling data (other than 100% batch testing or multivariate data analysis)
is used on HICs (where applicable), then Ppk and Cpk levels are greater than 1.67 and
492 1.33, respectively.
w If SCs, CCs or HICs (where applicable) are not capable, control plans are in place to
ensure that product is validated prior to shipment, and robust corrective action plans are
493 in place.
w Cpk values, if appropriate, are calculated for only processes that are stable and in
494 control.
Note:
Critical Characteristics (CC) - "Part or process requirements (dimensions, specifications,
tests, processes, assembly sequences, tooling, torque, welds, attachments, component
usages, etc.) which affect regulatory compliance or safe vehicle/product function and
require specific supplier, manufacturing, assembly, shipping, monitoring, and/or
inspection actions."
Significant Characteristics (SC) - "Categorized characteristics of products, processes,
and tests, where a reduction in variation, within a specified tolerance, around a proper
target will improve Customer satisfaction."
High Impact Characteristics (HIC) - Product or process characteristics that, when outside
of the specification tolerance, severely affect subsequent manufacturing operations or
customer satisfaction; the product or process is not, however, unsafe.
495
496
497 II.4.5
X Equipment capability for SCs, CCs and HICs (where applicable) must be demonstrated on all new w Supplier has procedures in place to qualify new equipment, specifically for SCs and
498 Rate this production equipment and tooling. CCs
499
sub- w Supplier can provide historical records of equipment capability on HICs.
element by
Note:
entering
Equipment capability is defined as a short-term capability study (Ppk).
500 r, y, or g in
cell above
501
502
For more information, refer to the AIAG Measurement Systems Analysis (MSA) manual
503 INC II.5. Measurement/Test Equipment Calibration and Use* (hyperlink below):
510 http://www.ctis.ford.com/fao_qualstandard/secure1/fao_qualstandard_toc_flat.html
511 II.5.1
512 X Supplier ensures that all measurement/test equipment is are available for use as identified in the w Supplier can validate measurement/test equipment availability per control plan.
Rate this control plan. The measurement/test equipment calibration and measurement/test equipment w Supplier has evidence that a published schedule is followed and on-track for the
sub- maintenance program ensures that back-up measurement/test equipment or a back-up calibration and maintenance of inspection, measuring and test equipment (including
513 element by measurement/test equipment process is available to support inspections/tests required by the test software).
entering control plan. w Measurement/test equipment procedures with visual aids are available where the
514 r, y, or g in measurements/tests are performed.
cell above
515
516 II.5.2 w Supplier has a measurement/test equipment R & R tracking mechanism in place.
X Variable measurement/test equiment is used for all SC's and CC's, if applicable, whenever w Both company and personal measurement/test equipment is evaluated and tracked.
517 Rate this possible. HIC measurement/test equipment, if applicable, is per the control plan. All
518 sub- measurement/test equipment (company and employee-owned) is identified per the control plan. w There is a process is in place to drive compliance.
519 element by w Is the tracking system automated or manual?
entering
r, y, or g in
cell above
23 of 31 Date Created: 4/4/03
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FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
II.5.2 All Expectations, regardless of Color Rating, shall have documented Action Plan
X Supplier must list evidence all support each Expectation.
Variable measurement/test equiment is used for to SC's and CC's, if applicable, whenever evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
Rate this possible. HIC measurement/test equipment, if applicable, is per the control plan. All
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
sub- measurement/test equipment (company and employee-owned) is identified per the control plan.
6 element by
entering Expectation Element G/Y/R DEFINITION: w If variable measurement/test equipment is not being used, supplier can provide solid
7
r, y, or g in justification as to why not.
520
cell above
521 w Attribute measurement/test equipment R&R studies are also done .
522
523 II.5.3
X Measurement/test equipment R & R is to conform with the guidelines in the AIAG Measurement w Measurement/test equipment R&R studies are to be completed for all
Rate this Systems Analysis (MSA) manual. Whenever measurement/test equipment R&R does not meet measurement/test equipment used to check Ford product regardless of type or
sub- these guidelines, specific plans are in-place which adhere to the guideline. ASTM R&R methods measurement system.
element by can be substituted where applicable.
entering
r, y, or g in
cell above
524
w Method and frequency of measurement/test equipment R&R is specified for every
measurement system, including attribute measurement/test equipment R&R.
525
w Where AIAG MSA guidelines are not met, an improvement plan is available.
526
Note:
It is recommended that measurtement/test equipment error be held within an acceptable
level. Measurement/test equipment with an error greater than 10% must be reviewed
527 against the tolerance and associated risks are evaluated.
Note:
Efforts must be made to conduct measurement correlation studies (i.e., a method of
inspection between the supplier and the receiving plant). Some of the measurement/test
equipment may require isolators to reduce the impact of the manufacturing equipment
vibration on the measurement .
528
529
530 II.5.4
531 X Supplier has a documented "dropped / damaged measurement/test equipment" policy that is w Operators know and understand the procedure
Rate this followed by all employees. This ensures that only functional, in-specification measurement/test w Records of dropped/damaged measurement/test equipment are in compliance
sub- equipment is used.
element by
entering
532 r, y, or g in
cell above
533
534 II.5.5
535 X Measurement and test equipment standards and masters are traceable to a national or w Supplier has a measurement/test equipment maintenance program.
Rate this international equivalent standard. Measurement and test equipment calibration and maintenance w Records show compliance. If supplier is using gauge blocks to qualify micrometers
sub- is performed on an appropriate schedule and per specification. All chemical standards are and calipers, then they are certified to National Institute of Standards & Technology
element by certified and are verified that expiration date has not been exceeded. (NIST) or international equivalent. All chemical standards are within their expiration
entering date.
536 r, y, or g in
537 cell above
538
24 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION:
539 INC II.6. Part Identification/Nonconforming Parts/Packaging/Shipping
546
547 II.6.1
X Supplier has a documented process for positive part/product identification in all stages of w Supplier has controls and processes in place for handling rework, repair, and scrap,
Rate this production, testing, laboratories, storage areas, office areas, etc. Records of release which include documentation, evaluation, segregation, quarantine, and disposition.
548 sub- authorization, where applicable, are available.
element by Note:
entering A good system should identify "where the part/product has been and where it is going."
r, y, or g in Everything has its place identified and it must be in its place. All parts/product outside of a
cell above production area (i.e., offices, labs, testing etc.) must have some means of identification.)
549
550
551 II.6.2
552 X Supplier has lot traceability of product after shipment to Ford. w Individual parts are identified for traceability, when and where feasible.
Rate this w Where supplier has lot traceability in operation, system is capable of communicating
sub- information to Ford, as required.
element by
entering
553 r, y, or g in
554 cell above
555 II.6.3
X Supplier takes measures to ensure that production processes control handling, storage, and w All aspects of part/product handling throughout the production process should be
Rate this packaging/containerization (e.g. rail cars, trucks, totes, drums, etc.) as to prevent damage or monitored for the occurrence of handling or storage damage. There should be
sub- deterioration, and preserve product quality. documented analysis and corrective action plans to eliminate the cause of functional
element by defects, and in the case of material - contamination.
entering
r, y, or g in
cell above
556
w Supplier has documented involvement in package/shipping container design and
557 testing, and improvements are being made to ensure product quality and integrity.
w Should supplier have responsibility for maintaining returnable dunnage, there is a
process for reviewing internal and external transportation bins for structural damage and
558 holes. (Potential for Hi-Lo forks causing product damage.)
w Supplier has a process for reviewing storage areas. All environmental and adverse
conditions are considered in the entire design of packaging/shipping mode and facilities.
559
w Returnable Ford dunnage is appropriately maintained and cleaned, if supplier
560 responsible. Measures are taken to repair or replace worn or broken dunnage.
561
562 II.6.4
563 X Supplier follows Ford part packaging requirements (Form 1750 - North America; Form 1750EU - w Supplier dunnage is Ford approved and documented.
Rate this Europe) where applicable, and all government shipping regulations and requirements where w Supplier complies with MS 9000/MMOG/Odette requirement, if applicable. Results
564 sub- applicable.. are available.
element by
entering
r, y, or g in
cell above
25 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
II.6.4 Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
X Supplier follows Ford part packaging requirements (Form 1750 - North America; Form 1750EU -
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
Rate this Europe) where applicable, and all government shipping regulations and requirements where
6 sub- applicable..
element by Expectation Element G/Y/R DEFINITION: w "Ford Plant Specific" packaging/shipping instructions are posted, when required.
7
entering
r, y, or g in
cell above
565
566
567
568 INC II.7 Testing/Engineering Specifications
575
576 II.7.1
X All inspections, measurements, and tests, including Engineering Specifications (ES) and Material w Supplier has a documented process in place to ensure that the latest Engineering
Rate this Specifications (MS), are performed according to documented control plans, instructions, and/or Specifications (ES), if applicable, and Material Specifications, if applicable, are
577 sub- procedures to ensure product requirements are met. accessible
element by w Supplier complies with all applicable blueprint and/or engineering specification and/or
entering material specification requirements
r, y, or g in
578 cell above
579
580 II.7.2
X Appropriate reaction plans address what actions should take place if there is a test or inspection w Supplier has a procedure for failing an engineering or material specification.
Rate this failure, and includes product containment and customer notification policy for all events.
sub-
element by
entering
r, y, or g in
cell above
581
w Reaction plans include directions on who is to act, if production is to stop, what
shipments are to stop or to be recalled, and what actions are deemed necessary to
582 protect and notify Ford.
583
584 II.7.3
X Suppliers and sub-suppliers providing heat-treated components are required to meet Ford w If heat treated parts are produced or used as a component to an assembly, supplier
Rate this Manufacturing Standard W-HTX and demonstrate compliance using the Ford Heat Treat System can verify that a valid system survey exists, for all heat treated components.
sub- Survey Guidelines. To reduce the risk of embrittlement, heat-treated steel components are
element by required to conform with Ford material specification WSS-M99A3-A.
entering
r, y, or g in
cell above
585
w If supplier does not meet the requirements, all non-conformances are documented and
586 action plans are in place.
587
588
589 INC II.8 Preventive Maintenance (PM) / Housekeeping*
26 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
Expectation
Completion Date
Responsibility
Expectation &
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
Rating
All Expectations, regardless of Color Rating, shall have documented Action Plan
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7
596 Expectation Element G/Y/R DEFINITION:
597 II.8.1
X Supplier has instituted practices that include reactive, preventive, and predictive maintenance. w Supplier has a process in place to improve the management, maintenance, and life-
598 Rate this The maintenance system supports process capability improvement. cycle of equipment and tooling.
sub- w Supplier's maintenance program includes a process for reviewing manufacturing
element by equipment and material handling systems (e.g., guards, conveyor belts, etc.)
599 entering
r, y, or g in w Supplier's maintenance department tracks unscheduled downtime versus scheduled
cell above downtime, and develops improvement actions to eliminate causes of unscheduled
600 downtime.
w Lessons from events due to unscheduled downtime are incorporated into the
601 scheduled maintenance program to improve OEE or equivalent.
w The maintenance schedule has specific responsibilities assigned and the scheduled
602 preventive maintenance (PM) is performed as required.
603 w Supplier's predictive maintenance is based on valid statistical methods.
604
605 II.8.2
606 X Management regularly reviews (at least quarterly) the status of the PM completion to plan. w There are minutes of management meetings related to the PM program.
Rate this Management reviews corrective action plans to ensure any backlog (past due) maintenance has a w Trend/performance charts demonstrate effectiveness of PM program (i.e., up-time
607 sub- plan to become current to the PM schedule. Management undertakes an evaluation to determine trend)
element by if there is a reduction of production equipment/process downtime. w New failure modes and causes identified from the PM program that affect part/product
entering quality (scheduled or unscheduled) have been looped back to the product's PFMEA,
608 r, y, or g in control plans, and work instructions.
cell above
609
610 II.8.3
X The supplier has continuous improvement plans for plant cleanliness, housekeeping, ergonomics, w There is a documented procedure for plant cleanliness and housekeeping
Rate this and working conditions, and audits their facility at least monthly. There is evidence that the
sub- supplier management team is following continuous improvement plans.
element by
entering
r, y, or g in
cell above
611
612 w There is adequate lighting for inspection, measuring, and test equipment
613 w Supplier's QOS has safety as one of the metrics
614 w Supplier's QOS tracks injuries related to ergonomic issues
615
616 II.8.4
X Supplier takes measures to minimize foreign material, chips, debris, contamination, excessive oil, w Supplier has a process to review manufacturing / repair / rework processing / storage
Rate this etc. where part/product quality and integrity can be negatively affected. and shipping areas for "any" potential to contaminate or damage finished parts/product,
sub- including the dunnage/shipping containers/tankers prior to shipping to customer plants.
element by
entering
r, y, or g in
cell above
617
27 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
II.8.4
X Supplier takes measures to minimize foreign material, chips, debris, contamination, excessive oil,
Expectation
Completion Date
Rate this etc. where part/product quality and integrity can be negatively affected.
Responsibility
Expectation &
Comments / Evidence
Sub-element
sub-
Expectation Guidelines
Due Date
Rating
element by
entering All Expectations, regardless of Color Rating, shall have documented Action Plan
r, y, or g in
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
cell above (*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: w Where supplier identifies areas of concerns, actions plans are developed to implement
618 improvements, and closure of issues is documented.
619
620
621 INC II.9 Manufacturing Flow / 6 Sigma and Lean Manufacturing Metrics*
628
629 II.9.1
630 X Supplier uses lean manufacturing and Six-Sigma principles, where applicable, for current and new If Supplier utilizes JIT production, the following are utilized:
631 Rate this model parts/product. JIT (just in time production) is used if applicable to the supplier's specific w Continuous flow processing, one piece flow or controlled batch size.
sub- industry. Waste elimination and team based structured problem solving are used to drive w Supplier only produces to customer demand (Takt).
632
element by continuous improvement for quality, process capability, and manufacturing efficiency.
633 w Supplier produces to replenishment Pull signal.
entering
634 w Supplier controls batch size by lowering changeover time (SMED).
r, y, or g in
635 cell above w Lean principles and Six Sigma are integrated into corporate objectives.
636 If applicable, Supplier utilizes autonomation, incorporating:
637 w A system that stops the process when defects are detected.
638 w Rapid supervisor alert, a signal that a defect has been detected.
639 w High intensity use of error-proofing
If applicable, supplier utilizes flexible labor processes and systems, by incorporating:
640
641 w The use of equipment that provides maximum efficiency and flexibility.
642 w Flexible standardized work sequences.
643 w Cell combination: Multiple product cell maximizing labor efficiency.
If applicable, supplier utilizes planned and structured workstation and cell Kaizan,
644 incorporating:
w Line side, metrics based problem resolution with team leaders. Operators and team
645 leaders improve effectiveness of work cell.
w Structured workstation-level improvement activity: Operators and team leaders
646 improve effectiveness of work cell.
w Structured cell-level improvement activity: A system that encourages metrics based
647 continuous improvement actions and recognizes employee contributions.
w Employee recognition program: A system that encourages continuous improvement
648 actions and recognizes employee contributions.
649
650 II.9.2
651 X A minimum of two lean (for non-capital intensive industries) and one Six Sigma measurable show w Supplier understands and, if applicable, uses lean and Six Sigma metrics
Rate this trends or history of improvement in the past six months. Lean measurables include the following: w Supplier uses lean manufacturing and Six Sigma principles to eliminate waste and to
sub- First Time Through (FTT), Overall Equipment Effectiveness (OEE), Dock to Dock (DTD), Build to manage its production, and these principles foster the use of measurables which are
element by Schedule (BTS), and Percent Value Add (PVA). For capital intensive industries, equivalent comparable to Ford's specified lean and Six Sigma metrics.
652 entering measurables should be available.
653 r, y, or g in w Lean and Six Sigma metrics are part of the supplier QOS
cell above w Lean and Six Sigma metrics are used to drive improvement and process variability
654 reduction.
655 w Lean and Six Sigma metrics are used to improve process capability
28 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
II.9.2
X A minimum of two lean (for non-capital intensive industries) and one Six Sigma measurable show
Rate this trends or history of improvement in the past six months. Lean measurables include the following:
Expectation
Completion Date
Responsibility
Expectation &
sub- First Time Through (FTT), Overall Equipment Effectiveness (OEE), Dock to Dock (DTD), Build to
Comments / Evidence
Sub-element
Expectation Guidelines
Due Date
element by Schedule (BTS), and Percent Value Add (PVA). For capital intensive industries, equivalent
Rating
entering measurables should be available. All Expectations, regardless of Color Rating, shall have documented Action Plan
r, y, or g in Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
cell above
(*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
6
7 Expectation Element G/Y/R DEFINITION: Note:
For more information and/or training, refer to the Lean Resource Center web page:
656 https://web.lean.ford.com/
657
658
659 INC II.10 Problem Solving/Corrective Actions
666
667 II.10.1
668 X Supplier uses a structured problem solving method (e.g., Global 8D) to address customer w Supplier has a documented problem solving methodology.
Rate this concerns and complaints. w Supplier has clearly described systemic root cause and corrective actions, which can
sub- be found in the actual process, work instructions, control plans, or procedures
669 element by
670 entering w There is a linkage to FMEAs and control plans.
r, y, or g in w Supplier uses Six Sigma and 8D principles and all of the appropriate statistical quality
671 cell above tools to identify root cause.
w Supplier shows evidence that Six Sigma metrics and 8Ds are driving to systemic
672 resolutions, and tracked and closed with Ford assembly plants on a timely basis.
w Work force is trained in problem-solving methodologies (e.g., Global 8D, Six Sigma
673 Green Belt/Black Belt)
w Supplier tracks internal quality issues, utilizing 6 Sigma DMAIC or 8D problem-solving
674 methodology.
w Supplier reviews pareto charts (or other analysis tool) of recent problems and
implements 6 Sigma project based error-proofing, where applicable.
Note:
Prioritization should be based on importance to the customer as defined by CTQ.
675
676
677 II.10.2
X Methods are established to communicate quality concerns to the supplier's production and w Supplier has a procedure to communicate corrective actions and process
Rate this support personnel. Corrective actions are submitted to the supplier's management team for improvements resulting from problem solving efforts within its organization and to similar
678 sub- review. The corrective actions are communicated to, and replicated in all affected areas in the areas.
679 element by supplier's organization. w CTQ Customer complaints are communicated to operators.
680 entering w Supplier includes appropriate production operators as part of the problem solving team
681 r, y, or g in w There is a process to capture lessons learned
682 cell above w Lessons learned are built back into the work instructions and procedures
683 w Lessons learned are incorporated in the current and new programs
684 w Supplier takes lessons learned and incorporates them into all similar processes.
685
686 II.10.3
X Supplier has a process in place to address customer plant concerns in a timely and thorough w If supplier's Q1 endorsement has been rescinded by a Ford customer plant based on
Rate this manner. the supplier demonstrated QR trend or 3MIS warranty R/1000 and CPU performance,
sub- the supplier has submitted a CAP (corrective action plan) to STA within 30 days
element by addressing the underlying root cause.
entering
r, y, or g in Note:
cell above Failure to do so may represent a 'violation of trust' and trigger a Q1 recommend revoke
687 signal in SIM.
29 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
FORD PROPRIETARY Q1 2002 Manufacturing Site Assessment Evaluation Matrix for Bulk Materials
6/1/2003
B E F G H I J K L M N
1 Date: E-Mail: STA Site Engineer:
2 Supplier Name: Phone#: E-Mail:
3 Supplier Site Code: If Supplier Self-Assessment, Approved By: Material name/specification number
4 Supplier Contact: Name:
5 Phone#:
II.10.3
X
Expectation
Completion Date
Supplier has a process in place to address customer plant concerns in a timely and thorough
Responsibility
Expectation &
Comments / Evidence
Sub-element
Rate this manner.
Expectation Guidelines
Due Date
Rating
sub-
element by All Expectations, regardless of Color Rating, shall have documented Action Plan
entering
Supplier must list evidence to support each Expectation. evidence listed. (Required for all Non-Compliances) Note: The Expectation Guidelines listed below are not to be considered all-
r, y, or g in (*Denotes Focus Area) inclusive. Refer to the AIAG Manuals to ensure compliance.
cell above
6
7
688 Expectation Element G/Y/R DEFINITION:
689 II.10.4
X Supplier reviews previous launches, if involved in past launches, and incorporates lessons w Supplier reviews its previous launches, if applicable, with Ford PD, Global Paint
Rate this learned in future launch plans to achieve flawless launch. Engineering, Materials Engineering, VO, and STA, utilizing an 8-D process to address
690 sub- issues.
element by w PD, Global Paint, Material Engineering lessons learned are formalized within the
691 entering supplier's design development system.
692 r, y, or g in w Supplier has a system in place to capture and archive lessons learned.
cell above w Supplier develops and implements agreed-upon work plans to assure successful
693 launches going forward.
694
30 of 31 Date Created: 4/4/03
Contact: Paul Norkevicius (pnorkevi@ford.com) Date Printed: 11/30/2010 Revision: 1
f8f9b5ea-1d8b-4853-b9cf-d6b9b1473d9a.xls (no longer draft effective 6/1/03)
Q1 2002 Site Assessment Summary Report
Date: Site Overall Rating: INCOMPLETE
Supplier Name: % Green Elements 0%
Green = (0) RED elements and (0) YELLOW elements - All elements are GREEN
Supplier Site Code: Yellow= (0) RED elements and (1) or more YELLOW elements # Green Elements 0
Red = (1) or more RED elements
STA Site Engineer: INC = (1) or more sub-elements not ranked RED, YELLOW or GREEN # Yellow Elements 0
# Red Elements 0
# INC Elements 15
Total # Elements 15
Element Sub-Element Due Date Element Sub-Element Due Date Element Sub-Element Due Date
INC I.1. Quality procedures/QS-9000/TS16949/QOS INC I.5. Manage the Change INC II.6. Part Identification/Nonconforming Parts/Packaging/Shipping
I.1.1 0 I.5.1 0 II.6.1 0
I.1.2 0 I.5.2 0 II.6.2 0
I.1.3 0 I.5.3 0 II.6.3 0
I.1.4 0 II.6.4 0
I.1.5 0 INC II.1. Sub-supplier Quality Management *
I.1.6 0 II.1.1 0 INC II.7 Testing/Engineering Specifications
I.1.7 0 II.1.2 0 II.7.1 0
I.1.8 0 II.1.3 0 II.7.2 0
I.1.9 0 II.1.4 0 II.7.3 0
I.1.10 0 II.1.5 0
I.1.11 0 II.1.6 0 INC II.8 Preventive Maintenance (PM) / Housekeeping*
I.1.12 0 II.1.7 0 II.8.1 0
I.1.13 0 II.8.2 0
INC II.2. Control of Incoming Quality II.8.3 0
INC I.2. FMEAs/Control Plans* II.2.1 0 II.8.4 0
I.2.1 0 II.2.2 0
I.2.2 0 II.2.3 0 INC II.9 Manufacturing Flow / 6 Sigma and Lean Manufacturing Metrics*
I.2.3 0 II.2.4 0 II.9.1 0
I.2.4 0 II.9.2 0
I.2.5 0 INC II.3 Control Plans / Operator Instructions*
I.2.6 0 II.3.1 0 INC II.10 Problem Solving/Corrective Actions
I.2.7 0 II.3.2 0 II.10.1 0
I.2.8 0 II.3.3 0 II.10.2 0
I.2.9 0 II.3.4 0 II.10.3 0
II.10.4 0
INC I.3. Employee Readiness/Training Review INC II.4 Process Variability Monitoring/Reduction*
I.3.1 0 II.4.1 0
I.3.2 0 II.4.2 0
I.3.3 0 II.4.3 0
II.4.4 0
INC I.4. APQP/Launch/PPAP/Run-at-Rate Review II.4.5 0
I.4.1 0
I.4.2 0 INC II.5. Measurement/Test Equipment Calibration and Use*
I.4.3 0 II.5.1 0
I.4.4 0 II.5.2 0
I.4.5 0 II.5.3 0
I.4.6 0 II.5.4 0
I.4.7 0 II.5.5 0
I.4.8 0
I.4.9 0
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