Docstoc

Sample Business Studies Assessment Task

Document Sample
Sample Business Studies Assessment Task Powered By Docstoc
					                                                        Q1 2002 Manufacturing
                                                           Site Assessment
                                                          Evaluation Matrix




                                                                                                 1 of 20
Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)   Date Printed: 7/29/2011         Date Created: 4/17/01
dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                          Last Revision: 4/22/2002 LBJ
Date:                                                                                        Supplier Contact:                                                               If Supplier Self-Assessment, Approved By:                    STA Site Engineer:
Supplier Name:                                                                               Phone#:                                                                         Name:                                                        E-Mail:
Supplier Site Code:                                                                          E-Mail:                                                                         Title:                                                                Part name and number(s)

                                                                                                                   Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                            Expectation                                                             Comments/




                                                                                                                                                                                                                                                                                              RESPONSIBILITY
                                                                                  YES / NO
                                                                                                                                                                                     Evidence




                                                                                                                                                                                                                                                                                                               Due Date
                                                                                                                                                                                                                                                   Action Plan
              Expectation                                                                                   Guidelines                                                           All Questions, regardless of 'Yes' or 'No', shall have      (Required for all Non Compliances)
                                                                                                                                                                                comments. Verify all documents. List part number(s)
                                                                                                Note: These comments are purely "Guidelines" for assessing each                                         viewed
                                                                                               Expectation. Supplier must list evidence to support each Expectation

 I. Planning for Manufacturing Process Capability (* denotes                                 I. Planning for Manufacturing Process Capability (*denotes focus
focus area)                                                                                  area)
 I.1. Quality procedures/QS-9000/QOS                                                         I.1. Quality procedures/QS-9000/QOS

                                                                                             o Supplier is third party certified to QS 9000 or TS 16949. Include the
I.1.1. Supplier's quality system is third-party certified to the QS-9000                     name of the registrar organization and the date of certification and/or re-
or TS 16949 requirements.                                                                    certification.
                                                                                             o Is certification current?
                                                                                             o Supplier reviews, on an annual basis, the internal audit procedures
                                                                                             and audits results/reports to ensure that all quality policies, procedures,
                                                                                             and work instructions are complete & accurate. Action plans are in
                                                                                             place for continuous improvements.
                                                                                             o There are records of revisions (change control) to procedures,
                                                                                             guidelines and work instructions that demonstrate that supplier's quality
 I.1.2. Supplier's quality system contains processes for all areas of the
                                                                                             system is being continuously improved.
site assessment. The quality system is updated as needed to drive
                                                                                             o Supplier's continuous improvement projects utilize quality tools,
continual improvements. Supplier's Senior Management Team,
                                                                                             including what impact these quality tools have on internal and external
including representatives from Manufacturing, Quality, Engineering,
                                                                                             metrics.
and Human Resources perform these reviews.
                                                                                             o 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.
                                                                                             o Supplier can identify what quality tools are being used and that trends
                                                                                             are being tracked.
                                                                                             o Supplier has records of 3 previous audits, including a list of all non-
                                                                                             conformities and non-compliances.
I.1.3. Nonconformances identified in prior third-party audits are not                        o For all non-conformances, action plans are in place. What
repeated.                                                                                    extraordinary efforts are in place to resolve recurring issues?
                                                                                             o Supplier links issues and corrective actions to customer satisfaction
                                                                                             o Supplier has evidence of the monthly QOS meetings, including what
                                                                                             metrics are being tracked and managed.
                                                                                             o Supplier has a strategy implementation process with defined roles
                                                                                             and responsibilities, and on-going actions with timing.
I.1.4. Supplier holds monthly QOS performance review meetings;                               o Cross-functional teams have been formed and working meetings are
supplier's Management Team, including representatives from                                   being conducted.
Manufacturing, Quality, Engineering, and Human Resources, should                             o There is evidence of cross-functional team meeting minutes, metrics,
perform these reviews.                                                                       and action items for monthly QOS meetings and daily production
                                                                                             meetings with senior plant management.
                                                                                             o Supplier is tracking trends to drive continuous improvement.
                                                                                             o Corporate strategy and objectives are linked to assure continuous
                                                                                             improvement of metrics.
                                                                                             o Supplier is tracking all Ford SIM metrics.
                                                                                             o Supplier's internal metrics include scrap, downtime, rework, and
I.1.5. QOS reviews include a review of all Ford SIM metrics, key
                                                                                             premium freight, etc.
process metrics, and customer satisfaction metrics.
                                                                                             o Supplier tracks warranty and has an evaluation process to determine
                                                                                             what drives improvement in warranty costs and customer satisfaction.

I.1.6. Plant-identified key QOS in-process metrics include, at a
minimum:




                                                                                                                                                            2 of 20
               Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                               Date Printed: 7/29/2011                                                                                                  Date Created: 4/17/01
               dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                               Last Revision: 4/22/2002 LBJ
                                                                                                                  Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                           Expectation                                                         Comments/




                                                                                                                                                                                                                                                                                     RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                Evidence




                                                                                                                                                                                                                                                                                                      Due Date
                                                                                                                                                                                                                                           Action Plan
             Expectation                                                                                   Guidelines                                                       All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                           comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                     viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

                                                                                            o Supplier has a method of analyzing and managing statistically
                                                                                            generated data (SPC charts) on the manufacturing process(es) that
                                                                                            produce Ford part(s).
                                                                                            o Cpk data is used to drive process enhancements that have an impact
                                                                                            on product characteristics (i.e., moving upstream to manage process
                                                                                            characteristics, such as, tool feed rate and speed, coolant temperature,
                                                                                            bearing failure rate, tool management strategy, etc.).
      -- Ppk/Cpk tracking mechanism.                                                        o Supplier has statistical evidence supporting the elimination of SPC
                                                                                            charting and replacing it with some other method of control (i.e., they
                                                                                            become part of a preventive maintenance program, tool management
                                                                                            program, die maintenance / replacement program, equipment vibration
                                                                                            analysis program, etc.).
                                                                                            o If supplier is not statistically monitoring process/product, how is
                                                                                            capability ensured?

                                                                                            o Both company and personal gages are evaluated and tracked
    -- Gage R & R tracking mechanism.                                                       o There is a process is in place to drive compliance
                                                                                            o Is the tracking system automated or manual?
                                                                                            o Supplier reviews, at a minimum, the Ford APQP manufacturing
                                                                                            elements to ensure proper tracking, documentation, and reaction plans
                                                                                            o Supplier's APQP implementation program is able to address the
                                                                                            following questions:
                                                                                                 1. What APQP tracking mechanism is being used? Are the latest
                                                                                            Ford
                                                                                                    guidelines for reporting being used and adhered to?
                                                                                                 2. Who are the APQP members? Does the cross-functional team
                                                                                            include representatives from engineering, manufacturing, material
                                                                                            control, purchasing, quality, sales, field service, subcontractors, and
                                                                                            customers, as appropriate.
    -- APQP tracking mechanism.
                                                                                                 3. Has there been a formation of sub-teams to develop PFMEA /
                                                                                            Control Plan /
                                                                                                     Work Instructions, etc.
                                                                                                 4. What is the communication method with team members? Is this
                                                                                            communication method adequate?
                                                                                                 5. How are program issues and concerns resolved?
                                                                                            o How many new programs is the supplier presently working on? Are all
                                                                                            new Ford programs being tracked according to the Ford APQP
                                                                                            Reporting Guidelines. Are action plans developed for any yellow or red
                                                                                            issue?
                                                                                            o There is evidence of management reviews for each program.
                                                                                            o Supplier's "quality manual" includes a procedure for internal audits
                                                                                            and corrective action implementation process
    -- Internal quality audit tracking mechanism.                                           o Supplier has an internal audit schedule and audits are being
                                                                                            performed according to schedule
                                                                                            o Does supplier use a "fresh eyes" concept?
                                                                                            o Supplier understands and uses lean metrics
                                                                                            o Supplier uses lean manufacturing to manage its production, and is
    -- Lean tracking, such as First Time Through (FTT), Overall
                                                                                            comparable to Ford's specified lean metrics.
   Equipment Effectiveness (OEE), Dock to Dock (DTD), Build-To-
   Schedule (BTS)
                                                                                            Note: For more information and/or training, refer to the Lean Resource
                                                                                            Center web page: http://webdev.lean.ford.com/
                                                                                            o Supplier assesses how much the TGW, CPU, and R/1000 are related
I.1.7. Final customer OS metrics include, at a minimum:                                     to supplier manufacturing and action plans are developed based on
                                                                                            those findings.




                                                                                                                                                          3 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                              Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                       Last Revision: 4/22/2002 LBJ
                                                                                                                 Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                           Expectation                                                        Comments/




                                                                                                                                                                                                                                                                                    RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                               Evidence




                                                                                                                                                                                                                                                                                                     Due Date
                                                                                                                                                                                                                                          Action Plan
              Expectation                                                                                  Guidelines                                                      All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                          comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                    viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

                                                                                            o Supplier has a tracking mechanism for TGW.

     -- Things Gone Wrong (TGWs) short term and long term                                   Note: Ford's Product Development can provide TGW information
                                                                                            Note: Short-term is defined as < 12 months; Long-term is defined as >
                                                                                            12 months
                                                                                            o Supplier has a tracking mechanism for CPU
     -- Warranty costs per unit short term and long term
                                                                                            Note: Short-term is defined as < 12 months; Long-term is defined as >
                                                                                            12 months
                                                                                            o Supplier has a tracking mechanism for R/1000
     -- Warranty repairs per 1,000 short term and long term
                                                                                            Note: Short-term is defined as < 12 months; Long-term is defined as >
                                                                                            12 months
                                                                                            o As part of its field return parts analysis, the supplier includes the
     -- Analysis of Field Return parts                                                      number of parts and root cause analysis, where possible
                                                                                            o Supplier has a procedure for customer satisfaction and is compliant

                                                                                            Note: Information can be obtained through JD Power or OEM
     -- Customer Satisfaction short term and long term.
                                                                                            Note: Short-term is defined as < 12 months; Long-term is defined as >
                                                                                            12 months

                                                                                            o Action items are being closed on time and show improvements.
I.1.8. Action plans to drive continual improvement of the above                             o These improvements are permanent in nature or are they short term
metrics are tracked at QOS review meetings.                                                 fixes?
                                                                                            o Is STA invited to supplier's QOS review meetings?
                                                                                            o Supplier's QOS High Mileage Reliability data includes 3 Months in
                                                                                            service (3 MIS) and 36 months in service (36 MIS)
I.1.9. QOS metrics should focus on low and high-time-in service.
                                                                                            o Supplier has developed projects based on High Mileage Reliability
                                                                                            data to improve product performance




                                                                                                                                                         4 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                             Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                      Last Revision: 4/22/2002 LBJ
                                                                                                                  Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                           Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                      RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                 Evidence




                                                                                                                                                                                                                                                                                                       Due Date
                                                                                                                                                                                                                                            Action Plan
              Expectation                                                                                  Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                            comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                      viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

I.2. FMEAs/Control Plans*                                                                   I.2. FMEAs/Control Plans*

                                                                                            o Supplier has documented process for developing DFMEAs, PFMEAs,
                                                                                            and control plans for all Ford parts
                                                                                            o Supplier obtains and reviews system and design FMEA or Design
                                                                                            Verification Plan & Report (DVP&R) from a System and/or Design &
                                                                                            Release Engineer to ensure that "effective and credible" PFMEA/Control
                                                                                            Plan/work instructions can be developed and implemented.
I.2.1. All Ford parts have documented design and process failure and                        o Supplier understands and documents processes that require defect
effects analysis (DFMEA, PFMEA), and Control Plans (or DCPs).                               prevention based on the development of FMEAs.
There is a robust process in place for developing these documents.                          o Supplier uses a process flow diagram or control plan when developing
                                                                                            a PFMEA/DFMEA.

                                                                                            Note: 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 identified as "Yellow".

                                                                                            o Supplier understands how to develop a robust FMEA (i.e.,
                                                                                            understands the process function, failure mode at that function, its
                                                                                            effects and causal factors, and detection methods)
                                                                                            o Supplier understands how to use the occurrence and detection rating.
                                                                                            o Supplier reviews performance data to validate the ratings.
                                                                                            o Supplier understands what quality tools, such as, cause & effect
                                                                                            (C&E) diagrams (based on process dominance such as "set up",
                                                                                            "machine", "fixture/pallet", "tooling", etc.), P-diagram, DOE, Value chain
                                                                                            mapping etc., were used and how analytical data was developed and
                                                                                            used to develop DFMEA (for Full service Supplier) and PFMEA.
                                                                                            o Supplier has a process to track FMEA revisions. Revision levels are
I.2.2. FMEAs are reviewed annually and actions are taken to drive to                        included on FMEAs.
lower Risk Priority Number (RPNs). A Pareto is used to focus on 1)                          o Does the supplier use the recommended Ford FMEA Manual or the
severity, 2) the product of severity and occurrence, and 3) to identify                     AIAG FMEA Manual?
high RPNs in order to prioritize actions to drive improvements.
                                                                                            Note: Specifying severity and occurrence ratings for SCs is equivalent
                                                                                            to establishing RPN thresholds. Rankings are subjective and therefore
                                                                                            cannot often be compared between parts. Let the highest severity &
                                                                                            criticality drive SC selection.

                                                                                            Note:
                                                                                            > 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: Must be driven by SFMEA/DFMEA. Ratings of "9" or "10"
                                                                                            are restricted to safety or government regulated.




                                                                                                                                                           5 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                               Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                        Last Revision: 4/22/2002 LBJ
                                                                                                                   Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                             Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                        RESPONSIBILITY
                                                                                  YES / NO
                                                                                                                                                                                   Evidence




                                                                                                                                                                                                                                                                                                         Due Date
                                                                                                                                                                                                                                              Action Plan
              Expectation                                                                                    Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                              comments. Verify all documents. List part number(s)
                                                                                                Note: These comments are purely "Guidelines" for assessing each                                       viewed
                                                                                               Expectation. Supplier must list evidence to support each Expectation

                                                                                             o Supplier has a process to move from detection to prevention.
                                                                                             o Supplier understands where there opportunities for poke-yoke.
                                                                                             o Supplier shows evidence that the error-proofing methods used are
                                                                                             effective.
                                                                                             o Supplier understands how to correlate prevention to CC's, SC's and
                                                                                             HIC's to determine effectiveness of the method (i.e., can address the
                                                                                             causal factor (failure mode)).
I.2.3. All defect detection areas are reviewed and plans exist to move                       o Supplier can directly relate the detection method to the cause of
to defect prevention. There is evidence that defect prevention is                            failure.
replacing defect detection.
                                                                                             Note: Poke-yoke helps in detection and should be derived from FMEA.
                                                                                             Poke Yoke is the practice of making defects impossible to create, so it is
                                                                                             a prevention method, not a detection method. Poke-Yokes should be
                                                                                             physically tested on the shop floor to ensure they work. Detection
                                                                                             methods are measurement systems and should be included in the
                                                                                             control plan and have regularly scheduled Gage R&R's performed.

                                                                                             o If a supplier is FSS, the SCs are defined on DFMEA

                                                                                             Note: SC's and HIC's are not necessarily restricted to part
                                                                                             characteristics. Process parameters are equally critical to the parts
I.2.4. Suppliers, in cooperation with its customers, have identified                         characteristics. The process parameters must also be identified as SC's
Significant Characteristics (SCs) and High Impact Characteristics                            and HIC's and must be monitored and managed through the control
(HICs) on their PFMEAs and Control Plans for every Ford part or                              plan.
family of Ford parts.
                                                                                             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 specification. Suppliers, full
                                                                                             service or not, cannot identify any characteristics as "CC" on their
                                                                                             o Supplier determines SC's and HIC's from the system/design FMEA
                                                                                             DFMEA/PFMEA
                                                                                             with additional characteristics identified by the PFMEA cross-functional
                                                                                             team.
I.2.5. Suppliers work with Ford Program Vehicle Teams (PVT),
Program Engineering Office (PEO), and STA to establish final                                 Note: For SC's and HIC's, severity rankings are between 5-8, with
agreement of SCs and HICs. Suppliers obtain specific agreement                               Occurrence rankings between 4-10.The product/process characteristics
from Ford for any parts not having SCs or HICs.                                              identified as SC, HIC and CC in the PFMEA must also be identified in
                                                                                             the control plan/work instructions. Additionally, rankings for CC (inverted
                                                                                             delta) and OS (operator safety) are severity = 9 or 10, with Occurrence
                                                                                             rankings between 1-10.
                                                                                             o There is evidence that annual lay-outs are completed
                                                                                             o All process or product characteristics being used to manage the
                                                                                             manufacturing process are identified on the control plan
I.2.6. Supplier ensures that all print dimensions and call-out notes on                      o All other dimensions not specified in the control plan have a
the engineering drawing are always met through control plans, work                           frequency of inspection identified in the layout report and in the quality
instructions, job set-up instructions, and receiving inspection                              procedure manual. (Annual lay-out can be considered)
Additional recommendation: "What are you doing to maintain a                                 o There is statistical evidence that supports sample frequency for all
particular dimension?"                                                                       print dimensions whether or not they are identified on the control plan.
                                                                                             o Process parameters that affect the quality characteristics of a part are
                                                                                             identified and controlled.




                                                                                                                                                             6 of 20
               Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                                Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
               dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                         Last Revision: 4/22/2002 LBJ
                                                                                                                    Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                             Expectation                                                             Comments/




                                                                                                                                                                                                                                                                                           RESPONSIBILITY
                                                                                  YES / NO
                                                                                                                                                                                      Evidence




                                                                                                                                                                                                                                                                                                            Due Date
                                                                                                                                                                                                                                                 Action Plan
              Expectation                                                                                    Guidelines                                                           All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                                 comments. Verify all documents. List part number(s)
                                                                                                Note: These comments are purely "Guidelines" for assessing each                                          viewed
                                                                                               Expectation. Supplier must list evidence to support each Expectation

                                                                                             o Supplier has specific controls in place that are robust in preventing
                                                                                             and containing non-conformances.
                                                                                             o Pass-through characteristics have been identified for all new parts
                                                                                             and existing parts. These pass-through characteristics are identified on
                                                                                             the PFMEA and control plan. (The intent is to implement robust controls
                                                                                             within the process control plans / work instructions to manage pass-
                                                                                             through characteristics.)
                                                                                             o Supplier has a process for identifying and managing pass-through
                                                                                             characteristics with sub-suppliers. This process includes obtaining data
                                                                                             from sub-suppliers to ensure that pass-through characteristics are
                                                                                             monitored and compliant.
I.2.7. Supplier verifies pass-through characteristics and ensures that                       o Pass-through characteristics are evaluated jointly between Ford's
zero defects are at Vehicle Operations (VO) and final customer.                              manufacturing engineering, product 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 have been
                                                                                             identified as SC's, CC's.)
                                                                                             o Supplier reviews error-proofing methods for all pass-through
                                                                                             characteristics. Action plans are in place to implement error-proofing
                                                                                             methods, where required.

                                                                                             Note: Pass-through characteristics are defined as: Those
                                                                                             characteristics which are produced at outside suppliers and
                                                                                             are transparent to the customer plant processes and controls.
                                                                                             Quality defects are at risk of being "passed through" to our
                                                                                             o Supplier measures First Time Through (FTT) at each step of the
                                                                                             process, and is included in the procedures when planning for future
                                                                                             product.
                                                                                             o For new manufacturing lines, there is evidence that FTT
                                                                                             measurement is planned and documented
I.2.8. FTT is measured at the source, corrective actions are
implemented and documented. The findings are extrapolated to
                                                                                             Note: First Time Through (FTT) is defined as: The percentage of parts
similar processes.
                                                                                             that complete a process and meet the quality requirements the first time
                                                                                             (not scrapped or reworked).

                                                                                             Formula: [Total parts Entering the Process - (Scrap + Rework)] / (Total
                                                                                             Parts Entering Process)
                                                                                             o Supplier can demonstrate linkage between DFMEA, PFMEA, Control
I.2.9. Control Plan is a result of appropriate quality planning and
                                                                                             Plan, Work Instructions, etc.
includes clear linkage between DFMEA and PFMEA.
                                                                                             o Control Plans / Work Instructions are readily available.

                                                                                             Note: Additional information on Control Plans can be found in the AIAG
I.2.10. Control Plans contain the following elements:                                        Advanced Product Quality Planning and Control Plan Reference manual
                                                                                             http://www.ctis.ford.com/fao_qualstandard/secure1/data/3223691.pdf

     -- Operation number / name
     -- Part Name / Part Number                                                              o Control plans identify the latest part level (suffix)
     -- Inspection Requirements
     -- Specifications                                                                       o Product and process specifications are included in the control plan




                                                                                                                                                                7 of 20
               Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                                   Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
               dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                            Last Revision: 4/22/2002 LBJ
                                                                                                               Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                         Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                    RESPONSIBILITY
                                                                              YES / NO
                                                                                                                                                                               Evidence




                                                                                                                                                                                                                                                                                                     Due Date
                                                                                                                                                                                                                                          Action Plan
          Expectation                                                                                    Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                          comments. Verify all documents. List part number(s)
                                                                                            Note: These comments are purely "Guidelines" for assessing each                                       viewed
                                                                                           Expectation. Supplier must list evidence to support each Expectation

                                                                                         o Control methods are specified in the PFMEA/control plan/work
                                                                                         instructions and are appropriate for the type of process.
                                                                                         o Work instructions define quality acceptance criteria
 -- Control Methods
                                                                                         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, etc.
                                                                                         o A cross-functional team is formed (including customer) to identify
                                                                                         SC's, CC's, HIC's, and ES
                                                                                         o SC, CC, HIC and ES control methods are consensed by the
  -- SC, CC, HIC, and Engineering Specifications (ES)                                    Component Review Team (CRT) (CC's are established by Ford only)
requirements are identified and appropriate                                              o All CC's, SC's, and HIC's from the PFMEA have been identified on
                                                                                         control plans.
                                                                                         o Engineering Specifications (ES) are identified by ES No. on control
                                                                                         plans
                                                                                         o Variable data is being collected, where appropriate.
                                                                                         o Listed process parameters and part characteristics are being
   -- SC, CC, HIC, and ES Control methods (in-process checks,                            controlled using the method identified in the control plan/work
   process gaging, and part gaging) are appropriate.                                     instructions.
                                                                                         o Gaging method is appropriate for the task and was specified during
                                                                                         the APQP process.
                                                                                         o Error proofing methods that are in place cannot be circumvented by
                                                                                         the operator and that poke yoke is on the plant's certification program
 -- Error proofing methods                                                               o Operator understands the reason for the error proofing method
                                                                                         o Error-proofing methods are tested for compliance
                                                                                         o Control methods (i.e., in-process gaging, poke yoke, visual
 -- In-process control methods                                                           inspection, etc.) are as specified in the PFMEA and control plan and/or
                                                                                         modified per the recommended actions
                                                                                         o Sampling plans are statistically sound (based on quantity and
 -- Sample Size and frequency                                                            variation) and justify probability of occurrence for a given cause or
                                                                                         failure mode.
                                                                                         o Required tools, gages, and other equipments are identified for sub-
 -- Required tools, gages, and other equipment
                                                                                         suppliers
                                                                                         o Reaction strategies (i.e. part containment, supervisor notification, line
                                                                                         shut-down, etc.) are specified for out of control conditions.
  -- Reaction Plans (Reaction plans must clearly direct the                              o Operator(s) understand the conditions for an "Out of Control" state
operator on how to act when a process begins to go out of control,                       o Reaction plans are adhered to (i.e. can provide when, why and what
or a product fails an inspection or test).                                               was done when an operation went down thru downtime sheets, end of
                                                                                         line metrics, etc.)




                                                                                                                                                         8 of 20
           Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                                Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
           dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                         Last Revision: 4/22/2002 LBJ
                                                                                                                   Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                            Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                       RESPONSIBILITY
                                                                                  YES / NO
                                                                                                                                                                                  Evidence




                                                                                                                                                                                                                                                                                                        Due Date
                                                                                                                                                                                                                                             Action Plan
              Expectation                                                                                   Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                             comments. Verify all documents. List part number(s)
                                                                                                Note: These comments are purely "Guidelines" for assessing each                                      viewed
                                                                                               Expectation. Supplier must list evidence to support each Expectation



I.3. Employee Readiness/Training Review                                                      I.3. Employee Readiness/Training Review

                                                                                             o Supplier has a selection criteria process to assign skilled operators to
                                                                                             a given function.
                                                                                             o There is evidence of skills management procedure
I.3.1. Supplier is responsible for assessing the skills required to
                                                                                             o Supplier manages its training to compensate for turnover rate.
perform all activities that affect product quality.
                                                                                             o There is a process to manage absenteeism, especially for a given
                                                                                             critical manufacturing process (which is based on severity and
                                                                                             occurrence).
                                                                                             o Supplier identifies operator skill set and training requirements for a
I.3.2. As part of the APQP process, employee staffing, skill                                 given program
requirements, and training are identified, and support program timing.                       o Staffing support for Capacity Planning Volumes takes into account
                                                                                             turnover rate and absenteeism
                                                                                             o Supplier has a training program and can demonstrate compliance to
                                                                                             training plans.
                                                                                             o Training is part of the supplier corporate objectives
                                                                                             o There is a process to determine training needs. "On the Job" training
                                                                                             recorded and managed
                                                                                             o There is a planned training program for each employee (hourly and
I.3.3. Employees have a skills assessment, training plan, and
                                                                                             salary).
evidence of training.
                                                                                             o There is a process in place to address a high turnover rate condition
                                                                                             o Operator qualifications/training records are readily available to the
                                                                                             production supervisor
                                                                                             o Training records of key salaried personnel (i.e., QC manager,
                                                                                             Incoming Receiving managers, etc.) are reviewed regularly for
                                                                                             compliance.
                                                                                             o Operators understand the application of the component they are
                                                                                             producing.
                                                                                             o Operators understand what is critical in the component and what
I.3.4. Supplier ensures that only trained and qualified personnel are                        could happen (consequence of failure mode) if it does not meet
involved in all aspects of the manufacturing of Ford Parts.                                  specification
                                                                                             o Operators are/were part of work instruction development process
                                                                                             o Operators are/were trained prior to performing the job
                                                                                             o Operators have the opportunity to provide feedback (related to the




                                                                                                                                                            9 of 20
               Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                               Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
               dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                        Last Revision: 4/22/2002 LBJ
                                                                                                                  Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                            Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                       RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                  Evidence




                                                                                                                                                                                                                                                                                                        Due Date
                                                                                                                                                                                                                                             Action Plan
              Expectation                                                                                   Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                             comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                       viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

I.4. PPAP Review and Run-at-Rate Review                                                     I.4. PPAP Review and Run-at Rate Review

                                                                                            o At a minimum, the warrant and inspection data are no more than one
I.4.1. PPAP documentation must be no more than one year old at the                          year old.
time of PSW submission, or at the discretion of the STA site engineer,                      o All PPAP levels are to the latest Ford and/or for FSS supplier's
STA resident manager, or customer plant. Ford Powertrain plants                             current design released print.
require a copy of the PSW when parts are shipped.                                           o The latest level PPAPs are made available for review, upon request,
                                                                                            for any Ford production or service part
                                                                                            o Supplier is compliant to PPAP (AIAG) procedures
                                                                                            o Supplier has a process for tracking "PPAPs with alert"
                                                                                            o If an alert is required, supplier includes the alert number and
                                                                                            description on the PSW under "Declaration --
                                                                                            EXPLANATION/COMMENTS." (Under "Submission Results", the box
I.4.2. All PPAP documentation must contain the information per the                          must be checked "NO")
PPAP manual published by the Automotive Industry Action Group                               o On PSWs with "alerts", the supplier has submitted a PPAP for these
(AIAG) - this information must also be available for Ford review.                           parts after the alerts have expired (alerts are normally for 90 days only).

                                                                                            Note: If the supplier has not submitted a PPAP for parts after the alerts
                                                                                            have expired, the supplier is not complaint and the buyer, product
                                                                                            engineer and the STA Resident must be notified.

I.4.3. Suppliers require sub-suppliers to have a process in place that                      o Supplier has a PPAP approval process for it's sub-suppliers
effectively satisfies all PPAP requirements regardless of sub-supplier                      o This procedure requires the supplier to conduct fit and functional
business relationship with Ford.                                                            approval on their sub-suppliers prior to PPAP submission to Ford
                                                                                            o The Ford specification WSS-M99P9999-A1 is included in the PPAP
                                                                                            submission under Appendix D, Production Part Approval - Material Test
                                                                                            Results. WSS-M99P9999-A1 gives material reporting requirements

                                                                                            Note: Refer to FSN, Environmental for the WSS-M99P9999-A1
I.4.4. Substance use restrictions conform with Ford environmental                           standard, and review supplier evidence of material reporting.
specification WSS-M99P9999-A1                                                               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.


                                                                                            o Supplier submits capacity verification documentation and is in
I.4.5. Run-at-Rate must be completed and supports the stated
                                                                                            compliance to all newly launched or added capacity parts.
program requirements (at full-volume production levels) for all Ford
parts.
                                                                                            Note: Confirm CPV with buyer, if unknown
                                                                                            o Supplier is compliant to Ford's product releases.
                                                                                            o Supplier communicates with its sub-suppliers using Electronic Data
                                                                                            Interchange (EDI) to support production requirements. If not, what
I.4.6. Supplier monitors capacity and has a process to ensure on-
                                                                                            mechanism is used? How effective is it?
going sufficient capacity on all Ford parts
                                                                                            o Supplier has a plan to support capacity requirements in case of
                                                                                            production interruptions due to equipment failure and/or sub-supplier
                                                                                            performance issues.
                                                                                            o Supplier complies with Ford's documented capacity verification
I.4.7. Run-at Rate must include the following elements and be                               procedure, referenced in FSN. (Run-at-Rate is part of the overall
performed on the entire process or the slowest operation (process                           Capacity Verification Process.)
bottleneck): machine available hours, shifts, days, machine downtime                        o Supplier's supporting documents demonstrate compliance to all newly
(planned and unplanned), machine change over, breaks, and quality                           launched or increased capacity parts.
or scrap.                                                                                   o Supplier provides timing on all newly launched or increased capacity
                                                                                            parts (i.e., Gantt charts)




                                                                                                                                                           10 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                                Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                         Last Revision: 4/22/2002 LBJ
                                                                                                                 Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                           Expectation                                                        Comments/




                                                                                                                                                                                                                                                                                    RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                               Evidence




                                                                                                                                                                                                                                                                                                     Due Date
                                                                                                                                                                                                                                          Action Plan
              Expectation                                                                                  Guidelines                                                      All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                          comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                    viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

I.5. Manage the Change                                                                      I.5. Manage the Change

I.5.1. Supplier has a documented process to effectively implement                           o Supplier has a documented manage the change procedure
post - Job 1 design changes, process changes, or volume changes.                            o Supplier can validate the procedure with a current example of a
                                                                                            change.
                                                                                            o Supplier has a process to implement internal and external suppliers'
I.5.2. Supplier effectively reviews and updates its quality supporting
                                                                                            (tier 2 or tier 3, etc.) proposed changes, which may or may not involve
documentation for these changes. Examples of documents that may
                                                                                            Ford.
require changes: FMEAs, Control Plans, Operator Instructions, Visual
                                                                                            o Supplier can demonstrate effective communication of a change.
Aids, and PPAP documentation.
                                                                                            o Supplier can validate the process using the most recent change,
                                                                                            o Supplier reviews each and every change and determines whether that
I.5.3. Supplier follows a documented process to ensure that proper
                                                                                            change requires customer approval.
Ford approvals are gained prior to making process changes. The
approval process will include use of Supplier Request for Engineering
                                                                                            Note: Refer to the manage the change procedure in the PPAP manual.
Approvals (SREAs), Change Request/Concern Report (CR/CR) in
                                                                                            SREA procedure is available on FSN.
Worldwide Engineering Release System (WERS), Management
Alerts, and revised PPAP documentation, as appropriate.




                                                                                                                                                        11 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                             Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                      Last Revision: 4/22/2002 LBJ
                                                                                                                   Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                            Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                       RESPONSIBILITY
                                                                                  YES / NO
                                                                                                                                                                                  Evidence




                                                                                                                                                                                                                                                                                                        Due Date
                                                                                                                                                                                                                                             Action Plan
              Expectation                                                                                   Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                             comments. Verify all documents. List part number(s)
                                                                                                Note: These comments are purely "Guidelines" for assessing each                                      viewed
                                                                                               Expectation. Supplier must list evidence to support each Expectation

II. Demonstration of Manufacturing Process Capability (* denotes                             II. Demonstration of Manufacturing Process Capability (* denotes
focus area)                                                                                  focus area)
II.1. Sub-supplier Quality Management *                                                      II.1. Sub-supplier Quality Management *

                                                                                             o Supplier has a defined process for managing its supply base,
                                                                                             including resources to work with sub-suppliers.
                                                                                             o Supplier has a process of identifying sub-suppliers with a high impact
                                                                                             on quality
II.1.1. Supplier has a defined process for managing its supply base                          o Supplier has a means of communication to notify high impact sub-
including identification of those with high impact to quality.                               suppliers of their status (i.e., e-mail, letter, meeting minutes, database
                                                                                             systems, etc.)?

                                                                                             Note: Communication includes FMEA's, control plans, pass-through
                                                                                             characteristics, and PPAP's.
                                                                                             o Sub-supplier compliance to QS 9000 or TS 16949 is demonstrated
II.1.2. Supplier requires sub-suppliers to be QS-9000 or TS 16949                            through self-assessment or third party registration.
compliant and verifies sub-supplier compliance by annual on-site                             o Supplier visits sub-suppliers on a predetermined frequency and
assessment of high impact sub-supplier facilities.                                           conducts on-site assessments
                                                                                             o Supplier has documented evidence of these assessments
                                                                                             o Supplier requires annual dimensional validation of all parts from sub-
                                                                                             suppliers (regardless of sub-supplier business relationship with Ford).
                                                                                             o Supplier verifies that sub-suppliers comply with the AIAG PPAP
                                                                                             manual.
                                                                                             o All parts have PPAP documentation, per the AIAG manual.
                                                                                             o When the supplier submits PPAP documentation to Ford, it contains
II.1.3. Supplier requires PPAP for all parts from sub-suppliers
                                                                                             sub-suppliers' PPAP information and/or it is available for review.
(regardless of sub-supplier business relationship with Ford).
                                                                                             o Supplier conducts fit and function testing on sub-suppliers'
                                                                                             components prior to getting PPAP approval from Ford. (This is used to
                                                                                             manage potential pass-through characteristics from tier 2 and 3
                                                                                             suppliers.)


                                                                                             o Supplier updates PPAP for any change in production part or process
II.1.4. When a PPAP is submitted to Ford, all sub-supplier PPAPs are
                                                                                             o PPAP documentation is not older than one year from the time of PSW
updated if the original PPAP documentation is more than one year
                                                                                             submission, unless otherwise specified by the Ford STA site engineer,
old, unless otherwise specified by the responsible Ford STA site
                                                                                             STA resident manager, or customer plant.
engineer, STA resident manager, or customer plant.
                                                                                             o Supplier has documented records of sub-suppliers' compliance to
II.1.5. Where Ford has defined an Engineering Specification (ES), or
                                                                                             engineering specifications or special characteristics
special characteristics that are the responsibility of the sub-supplier,
the sub-supplier must show compliance to the ES or special
characteristics in its PPAP submission to the Tier one supplier.
                                                                                             o Supplier has a process to identify and handle sub-supplier pass-
                                                                                             through characteristics, utilizing error-proofing methods.
                                                                                             o Robust controls are implemented within the process control plans /
II.1.6. Supplier requires sub-suppliers to take specific actions to                          work instructions to manage pass-through characteristics.
ensure that all pass-through characteristics are to customer                                 o Supplier can demonstrate that pass-through characteristics are
specifications.                                                                              analyzed on all new parts and planned for current parts.
                                                                                             o 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 plan.
                                                                                             o Supplier has a process to approve PPAP'd parts before they are
II.1.7. Supplier must confirm sub-supplier compliance by review and
                                                                                             incorporated into the process
approval of sub-supplier PPAP submission prior to incorporation of
                                                                                             o Supplier has a sub-supplier functional approval process for
product in supplier manufacturing process.
                                                                                             machining, raw materials, sub-assemblies, heat treat, plating, etc.




                                                                                                                                                           12 of 20
               Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                               Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
               dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                        Last Revision: 4/22/2002 LBJ
                                                                                                                   Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                            Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                       RESPONSIBILITY
                                                                                  YES / NO
                                                                                                                                                                                  Evidence




                                                                                                                                                                                                                                                                                                        Due Date
                                                                                                                                                                                                                                             Action Plan
              Expectation                                                                                   Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                             comments. Verify all documents. List part number(s)
                                                                                                Note: These comments are purely "Guidelines" for assessing each                                      viewed
                                                                                               Expectation. Supplier must list evidence to support each Expectation

                                                                                             o Supplier has a procedure in place that defines how to manage sub-
                                                                                             suppliers' generated defects (i.e., 8D review process), including
II.1.8. Supplier conducts systemic reviews with sub-suppliers and
                                                                                             permanent corrective action verification process
assures implementation of corrective actions across supplier facilities
                                                                                             o Supplier has a procedure in place to conduct random incoming quality
for all issues resulting in stop ship or field action.
                                                                                             audits to verify effectiveness of the corrective actions implemented by a
                                                                                             sub-supplier

II.2. Control of Incoming Quality                                                            II.2. Control of Incoming Quality

                                                                                             o Supplier's special characteristics are identified for incoming
II.2.1. Supplier has a strategy for receiving inspection.                                    inspection
                                                                                             o The frequency of inspection is greater on high
                                                                                             o Incoming quality is defined on control plans risk sub-suppliers
II.2.2. Incoming quality requirements are part of a control plan. If
                                                                                             o If incoming inspections are made, supplier shows compliance to the
incoming quality inspections are made, there is evidence of the
                                                                                             specifications
specification and compliance to the specification. If no incoming
                                                                                             o Supplier has supporting rationale if no incoming inspections are
inspections are made, there is a rationale for qualifying sub-suppliers.
                                                                                             made.
                                                                                             o Supplier has a containment policy for incoming quality (i.e., tagging,
                                                                                             identifying type of defect, log of defects, 8D review process).
II.2.3. Incoming Quality Operator follows a reaction plan if raw
                                                                                             o Supplier has a resolution process for incoming inspection rejects
material or purchased part is found to be out of specification.
                                                                                             o Supplier assigns responsibility for resolution, progress is being
                                                                                             tracked, and sufficient time is allocated to implement permanent
II.2.4. Supplier has appropriate resources to manage sub-supplier                            o Supplier has a
                                                                                             corrective action. process to review sub-supplier quality systems.
quality including on-site assessment of high impact sub-supplier                             o When non-conformities are present, supplier and sub-supplier have
facilities.                                                                                  specific reaction plans

II.3. Control Plans / Operator Instructions*                                                 II.3. Control Plans / Operator Instructions*

                                                                                             o Standardized operator instructions (including control plans, work
                                                                                             instructions, job aids, check sheets, job set-up instructions, and
                                                                                             illustrations) are developed and available to operators.
                                                                                             o Work instructions have all of the necessary details, including quality
II.3.1. Standardized operator instructions (including control plans,
                                                                                             acceptance criteria, process and product control parameters, reference
work instructions, job aids, check sheets, job set-up instructions, and
                                                                                             to product drawing release level and date, specific/special gages and
illustrations) are developed and available for operators.
                                                                                             tools required, reaction plan for process and product non-compliance,
                                                                                             point of contact, etc.
                                                                                             o Supplier can demonstrate operator compliance to the work
                                                                                             instructions.
                                                                                             o Operators are able to explain their work, including disposition of set-
II.3.2. Standardized operator instructions are legible, specific, and
                                                                                             up and scrap parts. They understand written instructions.
controlled. The instructions are available in the area where the work
                                                                                             o If there is a multi-lingual workforce, work instructions are translated
is being performed and are followed by operators as written.
                                                                                             o Visual instructions are present at the workstation
                                                                                             o Operators understand the consequences of non-compliant or suspect
                                                                                             parts and subsequent failure reaching the customer (i.e., downstream
                                                                                             operation or to the end customer)
                                                                                             o Supplier has a process of notifying customers if non-conforming
                                                                                             product has left the supplier's facility
II.3.3. Reaction plans are clearly defined and protect Ford from non-
                                                                                             o Supplier has a process if non-compliant parts get through the system
conforming materials.
                                                                                             o Work instructions specify a reaction plan if non-compliant parts get
                                                                                             through the system
                                                                                             o This procedure and/or reaction plan instructs the operator or quality
                                                                                             activity on what to do next

II.3.4. Control Plans are revised and updated when products or                               o Control plans are accurate and up to date with latest product/drawing
processes differ from those in current production.                                           and process revisions.




                                                                                                                                                           13 of 20
               Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                               Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
               dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                        Last Revision: 4/22/2002 LBJ
                                                                                                                    Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                             Expectation                                                             Comments/




                                                                                                                                                                                                                                                                                           RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                      Evidence




                                                                                                                                                                                                                                                                                                            Due Date
                                                                                                                                                                                                                                                 Action Plan
              Expectation                                                                                    Guidelines                                                           All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                                 comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                           viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

II.4. Process Variability Monitoring*                                                       II.4. Process Variability Monitoring*

                                                                                            o Supplier has a method to control processes (i.e., histogram, control
                                                                                            charts, in-line compensating units, etc.)
II.4.1. Supplier has determined appropriate statistical techniques. A                       o These methods of control are appropriate for the given process or
key aspect of defect prevention is the use of SPC to indicate when                          product characteristics (i.e., X bar - R chart, Individual Moving Range
action is necessary (such as adjustments and tooling changes), and                          chart, np charts, median charts, etc. -- SPC toolbox)
conversely, when processes should be left alone.                                            o The process is equipped with process controls, in-line gauging, etc.
                                                                                            o Supplier reviews data and makes appropriate improvements to the
                                                                                            process
II.4.2. Control charts are optimized for sample frequency, sample size,                     o The charts are being utilized to drive changes within the process
and appropriate chart type. SPC checks are performed on a timely                            o The charts capture what changes have been made to the process to
basis and out-of-control conditions prompt corrective action as                             enable verification that adjustment is beneficial to process (tooling
appropriate.                                                                                changes, machine down time, die change, etc.)
                                                                                            o SPC charts capture when a change has been made and that the
                                                                                            process has been effectively improved
                                                                                            o The charts are monitored for out of control conditions.
II.4.3. SPC data is maintained and monitored, and used to drive                             o The cause for an out of control condition is identified, including any
process and product improvements. Evidence of process                                       action to remedy condition.
improvements include: reductions in scrap, reductions in                                    o The charts are reviewed for recurring patterns and corresponding
rework/repair, increases in first-time through capabilities, and                            reaction plans are sufficient
reductions in machine downtime.                                                             o If a new cause has been identified, changes are driven back to
                                                                                            FMEAs/Control plan/work instructions
                                                                                            o The supplier conducts machine capability studies on processes that
                                                                                            are not statistically controlled (SPC)
                                                                                            o For all Ford design identified characteristics (SC's, CC's), short term
                                                                                            capability (Ppk) is > or = to 1.67 and long term capability (Cpk) is > or =
                                                                                            1.33.
                                                                                            o If variable data is used on HICs, then Ppk and Cpk levels are greater
                                                                                            than 1.67 and 1.33, respectively.
                                                                                            o If SCs, CCs or HICs or not capable, then robust corrective action
                                                                                            plans are in place.
                                                                                            o Cpk values in a process are stable and in control on an appropriate
                                                                                            control chart and the data represents long-term variation (i.e., includes
                                                                                            all major sources of variation, such as different lots of raw materials,
                                                                                            machine set-ups, tooling changes, etc.)
II.4.4. Ppk and Cpk levels are greater than 1.67 and 1.33,
respectively, for all SC, CC, and HICs.                                                     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




                                                                                                                                                               14 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                                    Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                             Last Revision: 4/22/2002 LBJ
                                                                                                                 Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                           Expectation                                                         Comments/




                                                                                                                                                                                                                                                                                     RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                Evidence




                                                                                                                                                                                                                                                                                                      Due Date
                                                                                                                                                                                                                                           Action Plan
             Expectation                                                                                   Guidelines                                                       All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                           comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                     viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

                                                                                            o Machine capability for SC's and CC's is conducted and improvements
                                                                                            are driving variability reduction.
                                                                                            o Machine capability for HICs is conducted and improvements are
                                                                                            made, if variable data is being used.
II.4.5. Machine capability for SCs, CCs and HICs is monitored and                           o When SPC chart shows that process is consistently out of control, the
improvements are made to drive variability reductions.                                      supplier understands and makes the proper process changes in order to
                                                                                            re-target to capability.

                                                                                            Note: Machine capability is defined as a short-term capability study
                                                                                            (Ppk).
                                                                                            o Supplier has procedures in place to qualify new equipment,
II.4.6. Machine capability for SCs, CCs and HICs must be
                                                                                            specifically for SC's and CC's
demonstrated on all new equipment and tooling.
                                                                                            o Machine capability is demonstrated on HICs, where applicable.




                                                                                                                                                         15 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                              Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                       Last Revision: 4/22/2002 LBJ
                                                                                                                  Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                           Expectation                                                         Comments/




                                                                                                                                                                                                                                                                                     RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                Evidence




                                                                                                                                                                                                                                                                                                      Due Date
                                                                                                                                                                                                                                           Action Plan
              Expectation                                                                                  Guidelines                                                       All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                           comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                     viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

II.5. Gage Calibration and Use*                                                             II.5. Gage Calibration and Use*

                                                                                            o Supplier has a documented gage control program, which includes
                                                                                            calibration labels.
                                                                                            o Supplier has a documented gage training program.
II.5.1. Supplier ensures that all gages are available for use as                            o Method and frequency of gage R&R is specified for every
identified in the control plan. The gage calibration and gage                               measurement system, including attribute gage R&R
maintenance program ensures that back-up gages or a back-up                                 o Gage control program includes a published schedule for the
gaging process is available to support inspections required by the                          calibration and maintenance of inspection, measuring, and test
control plan.                                                                               equipment, including test software
                                                                                            o There is evidence of a back-up plan if primary gaging method fails
                                                                                            o Operator is capable of gaging the part
                                                                                            o Gaging procedures with visual aids are posted at the work station
II.5.2. Variable gages are used for all SC and CCs. HIC gages are                           o Variable gages are used for all SCs and CCs, whenever possible.
per the control plan. All gages (company and employee-owned) are                            o Gage R&R studies are also done on attribute gages
identified per the control plan.
                                                                                            o Gages complement current print and product specification.
                                                                                            o Gage R&R studies are conducted per MSA requirements
                                                                                            o Gage R&R studies are to be completed for all gages used to check
                                                                                            Ford product regardless of type or measurement system. Gage R&R
                                                                                            studies are to conform with the guidelines in the AIAG Measurement
                                                                                            Systems Analysis Manual. Whenever gage R&R does not meet these
                                                                                            guidelines, specific plans are in place.

                                                                                            Note: Guideline for acceptance of gage repeatability and reproducibility
                                                                                            (% R & R) are, per MSA, page 60:
II.5.3. Gage R & R is to conform with the guidelines in the AIAG                            Under 10% error - the measurement system is acceptable
Measurement Systems Analysis manual. Whenever gage R&R does                                 10% to 30% error - may be acceptable based upon importance of the
not meet these guidelines, specific plans are in-place which adheres                        application, cost of gage, cost of repairs, etc.
to the guideline.                                                                           Over 30% error - measurement system need improvement. Make every
                                                                                            effort to identify the problems and have them corrected.
                                                                                            Note: It is recommend that gage error be held within an acceptable
                                                                                            level. Gages with an error greater
                                                                                            than 10% must be reviewed against the tolerance and associated risk.
                                                                                            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 gages may require isolators to reduce the
                                                                                            impact of the manufacturing equipment vibration on the measurement .
                                                                                            Note: It is important to know the difference between Gage R&R as a %
II.5.4. Supplier has a documented "dropped / damaged gage" policy                           o Tolerance and Gage R&R as a % of Total Variation. The former tells
                                                                                            of Supplier has a dropped/damaged gage policy and procedure
that is followed by all employees. This ensures that only functional, in-                   o Operators know and understand the procedure
specification gages are used.                                                               o Records of dropped/damaged gages are in compliance
                                                                                            o Supplier has a gage maintenance program. Is it computerized or
                                                                                            manual?
                                                                                            o Records show compliance. If supplier is using "Jo Blocks" to qualify
II.5.5. Gage masters are traceable to a national standard. Gage
                                                                                            micrometers and calipers, then they are certified to National Bureau of
calibration and maintenance is performed on an appropriate schedule
                                                                                            Standards/National Institute of Standards & Technology (NIST)
and per specification.
                                                                                            Note: Based on the product specification, it may be essential to have a
                                                                                            humidity-controlled environment to measure characteristics

                                                                                            II.6. Part Identification/Nonconforming Parts/Packaging/Shipping
II.6. Part Identification/Nonconforming Parts/Packaging/Shipping




                                                                                                                                                         16 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                              Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                       Last Revision: 4/22/2002 LBJ
                                                                                                                    Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                             Expectation                                                            Comments/




                                                                                                                                                                                                                                                                                          RESPONSIBILITY
                                                                                  YES / NO
                                                                                                                                                                                     Evidence




                                                                                                                                                                                                                                                                                                           Due Date
                                                                                                                                                                                                                                                Action Plan
              Expectation                                                                                    Guidelines                                                          All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                                comments. Verify all documents. List part number(s)
                                                                                                Note: These comments are purely "Guidelines" for assessing each                                         viewed
                                                                                               Expectation. Supplier must list evidence to support each Expectation

                                                                                             o Supplier has controls and processes in place for handling rework,
                                                                                             repair, and scrap, which include documentation, evaluation, segregation,
                                                                                             quarantine, and disposition.
II.6.1. Supplier has a documented process for positive part
identification in all stages of production, testing, laboratories, storage
                                                                                             Note: A good system should identify "where the part has been and
areas, office areas, etc.
                                                                                             where it is going." Everything has its place identified and it must be in its
                                                                                             place. (All parts outside of a production area (i.e., offices, labs, testing
                                                                                             etc.) must have identification tag).
                                                                                             o Supplier's lot traceability capabilities are communicated to Ford.
II.6.2. Supplier has lot traceability of product after shipment to Ford.                     o Individual parts are identified for traceability, when and where
                                                                                             feasible.
                                                                                             o Supplier has documented involvement in package design and testing,
                                                                                             and improvements are being made to ensure product quality
                                                                                             o Should supplier have responsibility for maintaining returnable
                                                                                             dunnage, there is a process for reviewing internal and external
                                                                                             transportation bins for structural damage and holes. (Potential for Hi-Lo
II.6.3. Supplier takes measures to ensure that production processes
                                                                                             forks causing product damage.)
control handling, storage, and packaging as to prevent damage or
                                                                                             o Supplier has a process for reviewing storage area for water leaks,
deterioration, and preserve product quality.
                                                                                             stacking method, height, etc.
                                                                                             o Storage areas are maintained and product protected from rust,
                                                                                             contamination, dust, etc.
                                                                                             o Does supplier store product outside? It is protected?
                                                                                             o Does supplier protect product from adverse environment?
II.6.4. Returnable Ford dunnage is appropriately maintained and                              o Supplier has a dunnage maintenance policy and procedure
cleaned. Measures are taken to repair or replace worn or broken                              o Does supplier store dunnage outside? Is it protected?
dunnage.                                                                                     o Does supplier protect dunnage from dusty environment?
                                                                                             o Supplier dunnage is Ford approved and documented.
                                                                                             o Supplier complies with MS 9000/MMOG/Odette requirement. Results
                                                                                             are available.
II.6.5. Supplier follows Ford packaging requirements. At pack-out, the                       o "Ford Plant Specific" packaging instructions are posted, when
Ford packaging guidelines are available for use and followed as                              required.
required.




II.7. Testing/Engineering Specifications                                                     II.7. Testing/Engineering Specifications

                                                                                             o Supplier complies with all blueprint and/or engineering specification
II.7.1. All inspections, measurements, and tests, including                                  requirements (ES, SDS, MS, etc.)
Engineering Specifications (ES) and Material Specifications (MS), are                        o Supplier has a documented process in place to ensure that the latest
performed according to documented control plans, instructions,                               Engineering Specifications (ES) are on file
and/or procedures to ensure product requirements are met.                                    o Supplier has the latest blueprint and/or engineering specification
                                                                                             requirements (ES, SDS, MS, etc.)
                                                                                             o Supplier has an engineering specification (ES) failure procedure,
II.7.2. Appropriate reaction plans address what actions should take
                                                                                             which includes product containment and customer notification policy for
place if there is a test or inspection failure.
                                                                                             all events.
                                                                                             o Supplier has an engineering specification (ES) failure procedure,
II.7.3. Reaction plans include directions on who is to act, if production
                                                                                             which includes product containment and customer notification policy for
is to stop, what shipments are to stop or to be recalled, and what
                                                                                             all events.
actions are deemed necessary to protect and notify Ford.




                                                                                                                                                              17 of 20
               Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                                  Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
               dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                           Last Revision: 4/22/2002 LBJ
                                                                                                                  Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                           Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                      RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                 Evidence




                                                                                                                                                                                                                                                                                                       Due Date
                                                                                                                                                                                                                                            Action Plan
              Expectation                                                                                  Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                            comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                      viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

II.7.4. Suppliers and sub-suppliers providing heat-treated components                       o Supplier meets W-HTX and demonstrates compliance to the Heat
are required to meet Ford Manufacturing Standard W-HTX and                                  Treat System Survey Guidelines and WSS-M99A3-A.
demonstrate compliance using the Ford Heat Treat System Survey                              o If supplier does not meet the requirements, all non-conformances are
Guidelines. To reduce the risk of embrittlement, heat-treated steel                         documented and actions plans are in place.
components are required to conform with Ford material specification
WSS-M99A3-A.

II.8. Preventive Maintenance (PM) / Housekeeping*                                           II.8. Preventive Maintenance (PM) / Housekeeping*

                                                                                            o Supplier has a documented maintenance program. Is it computer
                                                                                            driven or it manually managed?
                                                                                            o Supplier's maintenance program includes a process for reviewing
                                                                                            manufacturing equipment and material handling systems (i.e., guards,
II.8.1. Supplier has a maintenance system that contains reactive,
                                                                                            tears in the conveyor belts, etc.)
preventive, and predictive maintenance. The maintenance system
                                                                                            o Supplier's maintenance department tracks unscheduled downtime
supports process capability improvement.
                                                                                            versus scheduled downtime
                                                                                            o Events from unscheduled downtime are incorporated into the
                                                                                            scheduled maintenance program to improve first time through (FTT)
                                                                                            capability
II.8.2. The maintenance schedule has specific responsibilities                              o Supplier is compliant to the maintenance schedule.
assigned and the scheduled PM is performed as required.
                                                                                            o There are minutes of management meetings related to the PM
II.8.3. Management regularly reviews (at least quarterly) the status of                     program.
the PM completion to plan. Management reviews corrective action                             o Trend/performance charts demonstrate effectiveness of PM program
plans to ensure any backlog (past due) maintenance has a plan to                            (i.e., up-time trend)
become current to the PM schedule. Management undertakes an                                 o New failure modes and causes identified from the PM program that
evaluation to determine if there is a reduction of machine/process                          affect part quality (scheduled or unscheduled) have been looped back to
downtime.                                                                                   the product's PFMEA, control plans, and work instructions.
                                                                                            o There is a documented procedure for plant cleanliness and
II.8.4. The supplier has continuous improvement plans for plant
                                                                                            housekeeping
cleanliness, housekeeping, ergonomics, and working conditions, and
                                                                                            o There is adequate lighting for inspection, measuring, and test
audits their facility at least monthly. There is evidence that the
                                                                                            equipment
supplier management team is following continuous improvement
                                                                                            o Supplier's QOS has safety as one of the metrics
plans.
                                                                                            o Supplier's QOS tracks injuries related to ergonomic issues
                                                                                            o Supplier has a process to review manufacturing / repair / rework
                                                                                            processing and shipping areas for "any" potential to contaminate
                                                                                            finished parts, including the dunnage prior to shipping to customer
                                                                                            plant(s) (e.g., finished machined parts, bearings, seals/gaskets, brakes,
II.8.5. Supplier takes measures to minimize foreign material, chips,                        fuel and power steering lines, hoses, etc. cannot accept "any"
debris, contamination, excessive oil, etc. where part quality can be                        contamination. Contamination in the raw materials for injection molded
negatively affected.                                                                        and powdered metal components can impact product quality and
                                                                                            performance.).
                                                                                            o Where supplier identifies areas of concerns, actions plans are
                                                                                            developed to implement improvements, and closure of issues is
                                                                                            documented.

II.9. Manufacturing Flow / Lean Manufacturing Metrics*                                      II.9. Manufacturing Flow / Lean Manufacturing Metrics*




                                                                                                                                                          18 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                               Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                        Last Revision: 4/22/2002 LBJ
                                                                                                                  Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                            Expectation                                                         Comments/




                                                                                                                                                                                                                                                                                      RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                 Evidence




                                                                                                                                                                                                                                                                                                       Due Date
                                                                                                                                                                                                                                            Action Plan
              Expectation                                                                                   Guidelines                                                       All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                            comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                      viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation

II.9.1. Supplier uses a Lean manufacturing system for current parts                         o Supplier can demonstrate implementation of lean manufacturing on
based on the use of 5S, standardized work, Total Preventive                                 the shop floor (e.g. 5S (Sort, Stabilize, Shine, Standardize, Sustain),
Maintenance (TPM) and empowered work teams. Work teams are                                  Kaizen, Six Sigma, Cell manufacturing, etc.)
responsible for problem solving at the work station. Batch sizes are                        o Supplier has a procedure for work in process inventory on the shop
minimized through reduced equipment change over time.                                       floor and/or in the warehouse, on site or off site. Does supplier
                                                                                            practice pull or push system?
                                                                                            o Supplier has "quick change tooling" capability to improve overall
                                                                                            equipment effectiveness (OEE)
                                                                                            o Supplier's lean metrics are equivalent to Ford metrics




II.9.2. A minimum of two Lean measurables show trends or history of                         o Lean metrics are part of the supplier QOS
improvement in the past six months. Lean measurables may include                            o If data does not reflect positive trends, actions are in place to improve
at least two of the following: Dock to Dock (DTD), First Time Through                       them
(FTT), Overall Equipment Effectiveness (OEE), Build-To-Schedule
(BTS), and Value Add Percentage.




                                                                                                                                                          19 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                               Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                        Last Revision: 4/22/2002 LBJ
                                                                                                                  Q1 2002 Manufacturing Site Assessment Evaluation Matrix



                                                                                                            Expectation                                                          Comments/




                                                                                                                                                                                                                                                                                       RESPONSIBILITY
                                                                                 YES / NO
                                                                                                                                                                                  Evidence




                                                                                                                                                                                                                                                                                                        Due Date
                                                                                                                                                                                                                                             Action Plan
              Expectation                                                                                   Guidelines                                                        All Questions, regardless of 'Yes' or 'No', shall have   (Required for all Non Compliances)
                                                                                                                                                                             comments. Verify all documents. List part number(s)
                                                                                               Note: These comments are purely "Guidelines" for assessing each                                       viewed
                                                                                              Expectation. Supplier must list evidence to support each Expectation


II.10. Problem Solving/Corrective Actions                                                   II.10. Problem Solving/Corrective Actions

                                                                                            o Supplier has a documented problem solving methodology.
                                                                                            o Supplier has clearly described systemic root cause and corrective
                                                                                            actions, which can be found in the actual process, work instructions,
                                                                                            control plans, or procedures
                                                                                            o There is a linkage to FMEAs and control plans
                                                                                            o Supplier uses 8D principles and all of the quality tools to identify true
II.10.1. Supplier uses a structured problem solving method (e.g.,
                                                                                            root cause
Global 8D) to address customer concerns and complaints.
                                                                                            o Supplier shows evidence that 8Ds are driving to systemic resolutions,
                                                                                            and tracked and closed with Ford assembly plants on a timely basis.
                                                                                            o Work force is trained in problem-solving methodologies
                                                                                            o Supplier tracks internal quality issues, utilizing an 8D problem-solving
                                                                                            methodology.

                                                                                            o Supplier has a procedure to communicate 8Ds within its organization
                                                                                            o Customer complaints are communicated to operators
                                                                                            o 8Ds are communicated down to the operator level
II.10.2. Methods are established to communicate quality concerns to
                                                                                            o Supplier includes production operators as part of the problem solving
the supplier's production and support personnel. 8D actions are
                                                                                            team
submitted to the supplier's management team for review. The 8D
                                                                                            o There is a process to capture lessons learned
corrective actions are communicated to affected areas in the
                                                                                            o Lessons learned are built back into the work instructions and
supplier's organization.
                                                                                            procedures
                                                                                            o Lessons learned are incorporated in the current and new programs

II.10.3. Customer concerns in SIM and quality rejects show improving                        o Supplier can access SIM and review QR details on a daily basis.
trends or are at zero level.




                                                                                                                                                           20 of 20
              Contact: Laura Blair Johnson (lblair@ford.com) or Bonnie Fagerson (bfagerso@ford.com)                                                Date Printed: 7/29/2011                                                                                           Date Created: 4/17/01
              dd292d7d-aec6-452c-9ebc-2c7a0459eaf0.xls                                                                                                                                                                                                         Last Revision: 4/22/2002 LBJ

				
DOCUMENT INFO
Shared By:
Categories:
Tags:
Stats:
views:16
posted:7/29/2011
language:English
pages:20
Description: Sample Business Studies Assessment Task document sample