Processsignoffedition5 5 PDF

Process Sign-Off
Edition 5.5
PSO
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
PROCESS SIGN-OFF
(PSO)
Edition 5.5
December 2006
INTENTIONALLY LEFT BLANK
Process Sign-Off (PSO)

FOREWARD TO THE 5.5 EDITION
This manual shall define the requirements for Process Sign-Off (PSO) and detail the
documentation required to verify conformance to DaimlerChrysler's (DCC) Quality System
Standards. The PSO, ISO/TS-16949 and Chrysler Development System (CDS) will form
the foundation for Supplier readiness to assure proactive Advanced Product Quality
Planning. A Suppliers certification to ISO/TS-16949 alone is not sufficient for PSO
approval; all PSO requirements must be met in order to assure conformance to
dimensional, material, functional and (where necessary) appearance requirements. In
addition, it should be noted that every external Supplier of production parts to
DaimlerChrysler Corporation shall be ISO/TS-16949:2002 third party registered. Effective
01/01/2007, all requirements stated in this document apply to all DaimlerChrysler
Production Suppliers, including sub-tier Suppliers.
In order to achieve an appreciable improvement in part quality, this manual has been
modified to reflect DaimlerChrysler Corporations current PSO philosophy. Emphasis is
placed on the importance of adhering to our Product Creation Process, i.e. the Chrysler
Development System (CDS). This manual should be reviewed carefully and in its entirety
to assure that all PSO requirements are known and understood. The 25 PSO Process
Elements identified in the 5th Edition PSO Manual were re-evaluated and, in some cases,
modified or removed.
The name DaimlerChrysler and DCC, as used in this manual, refer to DaimlerChrysler
Corporation (i.e., DCC formerly known as Chrysler Corporation) and its subsidiaries,
which manufacture Chrysler, Dodge and Jeep brand vehicles. This manual does not
apply to other DaimlerChrysler AG subsidiaries or operations, which manufacture
Mercedes-Benz, Freightliner or other brand vehicles or products. Where the word
Supplier is used in this manual, it is intended to indicate both external and internal Tier
1 Suppliers. Where the term DCC PSO Team is utilized, it denotes DaimlerChrysler
Employee involvement only. The term PSO team indicates all individuals involved in the
PSO process (i.e., DCC and Supplier).
For questions or comments concerning the Process Sign-Off manual, please contact your
DaimlerChrysler Advance Supplier Quality Planning Specialist (ASQP Specialist).
ACKNOWLEDGMENTS
PROCESS SIGN-OFF (PSO)

Edition 5.5
Process Sign-Off 5.5 Revision Team Members
David Eller
Mgr - AQP Strategy & Processes
Bryan Book
AQP Strategy & Processes
Nance Taylor
Vic Randolph
Eric Helgeson
ASQP - BIW/Exterior
Larry D'Agostino
ASQP - Chassis
Simon Kissonergis
ASQP - Electrical/Electronics
Cris Miller
ASQP - Interior
Neil Murphy
ASQP - Powertrain
Ida Goodwill
CDS
Dennis Fett
Corporate Quality
Chris Cottam
Manufacturing Quality
Lynn Yang
Powertrain Quality
Mary Clor
Process Quality Engineering
Arno Reiter
Supplier Quality - Graz
Dave Koski
ASQP - AQP/PSO University
Hector Magaa
Supplier Quality - Mexico
Requests for revisions or changes to the manual

should be directed to the PSO 5.5 Revision Team
PROCESS SIGN-OFF (PSO)

Table of Contents
Page
Introduction ............................................................................................................ 1
Process Sign-Off Flow Chart & Responsibilities ......................................................... 6
Process Sign-Off Element Requirements.................................................................. 11
Appendix A Forms and Instructions ......................................................................... 45
Appendix B Tables and Examples ........................................................................... 61
Appendix C FTC Calculations .................................................................................. 67
Appendix D PSO Extended Run ............................................................................... 79
Appendix E Forever Requirements ........................................................................... 81
Appendix F Internal PSO Requirements .................................................................... 87
Frequently Asked Questions .................................................................................... 93
Reference Manuals................................................................................................. 98
Glossary ................................................................................................................ 99
Index................................................................................................................... 111
Process Sign-Off (PSO)

INTRODUCTION
SCOPE:
Process Sign-Off (PSO) shall be performed on all new or modified parts with
PPAP requirements or parts that have been out of production for 12 months
or longer. Additional conditions that may result in a PSO being required are:
Carry-over parts with historically high warranty and/or quality
problems;
Carry-over parts which have experienced a Supplier responsible yard
hold within the past calendar year;
New and/or additional production lines (e.g. capacity increases);
Production line moves, within a year of PSO approval;
Any product or process change that occurs during the lifecycle of a part
or system.
PROCESS SIGN-OFF DEFINITION

WHAT IS A PSO?
Process Sign-Off is a formal review of the Supplier's production
manufacturing process. This process verifies a Suppliers ability to
manufacture production material at the daily tool capacity (as noted on the
Production Purchase Order or as provided in writing by the DCC Production
Buyer).
Each PSO includes evaluation of associated production facilities, related
manpower, equipment, material, methods, procedures, software level(s) and
tooling. The PSO is utilized to scrutinize the Suppliers entire production
process, including all in-house and secondary systems that support primary
production line(s).
The DaimlerChrysler PSO is composed of three primary activities:
1. Pre-PSO Meeting
The DCC PSO Team shall review PSO documentation during AQP meetings
and again during the Pre-PSO Meeting for compliance to PSO
requirements.
2. PSO On-site Visit
The DCC PSO team shall witness at least one Production Demonstration
Run (PDR) utilizing completed production tools as part of the PSO process
for all Collaborative and Directed AQP Activity Level parts. PSO activities
shall be conducted by the Supplier for all Self-Directed AQP Activity Level
parts. Data collection, analysis, and summarization are the true measures
of part quality and production capabilities. Observing the PDR should
reveal issues such as bottlenecks and inefficiencies. Production Process
review and measurements will provide the production rate, First Time
Capability (FTC) and other statistics that validate each Suppliers ability to
effectively produce both the required quality and product quantities.
Full compliance with all PSO requirements and procedures ensures that
the Suppliers manufacturing process is stable, in control and capable of
producing parts that meet all requirements.
3. Validation Testing
Production Validation (PV) Testing, of the Production Demonstration parts,
will validate the Suppliers system and provide evidence that the parts
meet engineering, quality, durability, and reliability requirements
contained in the Performance, Process, and Material Specifications.
Packaging and shipping or simulation test approvals are required by
Material Handling Engineering if applicable.
WHY IS A PSO NECESSARY?

Process Sign-Off is an effective method of verifying a Suppliers quality
planning processes. It confirms that the processes can and will (when
properly and successfully executed) produce quality parts in sufficient
quantities for production.
WHO CONDUCTS THE PSO?

The PSO Team consists of, at a minimum, the DCC ASQP Specialist, DCC
Product Engineer and Supplier(s) Representatives.
Other PSO team members may include but are not limited to; the DCC
Buyer, Center of Competence (COC) Engineer, and Vehicle Specialist.
The DCC ASQP Specialist has lead responsibility for the PSO for parts or
modules with Collaborative and Directed AQP Activity Levels.
The Supplier has lead responsibility for parts with Self-Directed AQP
Activity Levels.
The Supplier shall identify Supplier PSO team members for both the
DaimlerChrysler led PSOs, as well as for Supplier led Self-Directed PSOs.
WHEN IS THE PSO PERFORMED?

The Process Sign-Off, On-Site Visit shall be scheduled by the PSO Team
following the Pre-PSO Documentation Review, when the PSO Team agrees
that:
All required Supplier documentation has been reviewed and is acceptable;
Production tooling is complete, on-site at the Supplier's Plant, setup,
debugged and the Supplier Readiness Evaluation (SRE) performed;
SRE is complete and the results have been documented and are
acceptable to the team; and
The production operators are trained and capable of running at the
required line speed.
The purpose of the PSO is to demonstrate Supplier process capability and production
capacity. The PSO demonstration shall produce dimensionally correct parts on the homeline with production tooling. The requirement is to complete all PSOs and PPAP
submissions prior to supplying parts for S1 Start. If PPAP is not complete prior to S1
Start, an Interim Approval Authorization (IAA) is required. For specific requirements

regarding IAA submission, refer to P&S procedure PSSP0108 as well as any special
requirements of the specific DCC Product Team. Suppliers do not have access to this
procedure and should contact their DCC ASQP Specialist or Engineer for additional
information regarding IAAs.
HOW IS THE PSO PERFORMED?

Refer to Figure 1 for the PSO strategy and Figures 2.1 and 2.2 for a step-bystep flowchart and responsibility matrix for the PSO process.
Pre-PSO Meeting:
The DCC ASQP Specialist will initiate PSO dialogue with the DCC Product
Engineer and the Supplier (i.e., for Directed and Collaborative PSOs).
Together, they will schedule and coordinate the Pre-PSO Meeting as well as
the PSO On-Site Visit. The ASQP Specialist will advise the Supplier of the
documentation the team will want to review and whether the part has been
selected for a PSO Extended Run.
Process Sign-Off On-Site Visit:
The PSO Team shall complete the first 20 elements of the PSO SUMMARY
REPORT at the Suppliers manufacturing facility. The PSO Team shall also
verify the Suppliers compliance to all 21 elements of PSO Edition 5.5
before full approval is given. Any deviations shall be recorded on the PSO
COMMENTS SHEET. A successful PDR shall yield parts for Production
Validation (PV) Testing.
When appearance approvals are required, the Supplier shall obtain a signed Appearance
Approval Report (AAR) prior to PPAP submission. Refer to the AIAG PPAP manual and
DCC Engineering Standards CS-9022 and PS-4559 for further guidance.
PSO Z Approval: Z Approval is an internal code within the Powerway.com system.
This code, in conjunction with the submission of a dimensional Part Submission Warrant
(PSW), indicates that the first 20 PSO elements have been completed and approved. At
this point, the Supplier may be eligible for partial tooling payment (for further tool
payment information, reference the source package and the DCC Purchasing contact
noted there in). The ASQP Specialist is responsible for entering the Z approval into
Powerway.com for Directed and Collaborative AQP Activity Level parts. The Supplier is
responsible for entering the Z approval into Powerway.com for Self-Directed AQP Activity
Level parts. Z approval authorizes the Supplier to submit the Dimensional Part
Submission Warrant (PSW) into Powerway.com.
PSO A Approval: The A Approval is an internal code within Powerway.com. This
code, in conjunction with the submission of a material and/or functional PSW (and an
AAR, if required) confirms that all PSO and PPAP requirements have been met. The
Supplier is then eligible for full tooling payment. The ASQP Specialist is responsible for
entering the A approval into Powerway.com for Directed and Collaborative AQP Activity
Level parts. The Supplier is responsible for entering the A approval into Powerway.com
for Self-Directed AQP Activity Level parts.
The PSO date and an A disposition are required to be entered into Powerway.com prior
to the Supplier submitting the Warrant (PSW) and entering the PPAP date and PPAP A
disposition. This requirement is true for all parts, regardless of AQP Activity Level.
PSO N Approval: The N disposition is an internal code within Powerway.com. This
code indicates that the PSO On-Site Visit was unsuccessful and corrective action is
required by the Supplier. A new PSO planned visit date (or corrective action completion
date) is required to be entered into Powerway.com.
Interim Approval Authorization
All parts require full PSO and PPAP approval. PSO A approval is a prerequisite for PPAP
approval. PPAP approvals are submitted through Powerway.com by the Supplier. Failure
to submit PPAP before S1 Start will require an Interim Approval Authorization (IAA).
Reference the internal DCC procedure PSSP0108. Suppliers do not have access to this
procedure and should contact their DCC ASQP Specialist or Engineer for additional
information regarding IAAs.
NOTE 1: Even with Z Approval, an IAA is still required.
NOTE 2: Any deviations to the PSO requirements outlined in this manual must be
requested and approved in writing by the DCC ASQP Specialist and Product Engineer,
REGARDLESS OF AQP ACTIVITY LEVEL. Approval(s) must be obtained from DCC
before completion of the PSO process. Requested deviation(s) shall be formally outlined
in detail within the COMMENT SHEET of the completed PSO.
PROCESS SIGN OFF STRATEGY

REVIEW PSO
REQUIREMENTS WITH
PSO TEAM
& SUPPLIER
SUPPLIER PERFORMS
READINESS EVALUATION
RUN
CONDUCT PRE-PSO
MEETING (REVIEW
SUPPLIERS
DOCUMENTATION & SRE)
PSO TEAM CONDUCTS

PSO ON-SITE VISIT or
SUPPLIER PERFORMS
PRODUCTION
DEMONSTRATION RUN
(Self Directed AQP)
SUPPLIER CONDUCTS
PV TESTING
PSO TEAM
COMPLETES
PROCESS SIGN-OFF
SUPPLIER SUBMITS PPAP

PART SUBMISSION
WARRANT
SUPPLIER COMPLIES WITH

CONTINUOUS
CONFORMANCE
REQUIREMENTS
PROCESS SIGN-OFF FLOWCHART

1
PART ENTERS
POWERWAY.COM
2
INITIAL RISK
EVALUATION
& AQP LEVEL
Self Directed AQP
Collaborative/Directed AQP
4
DAIMLERCHRYSLER
LED PSO
3
SUPPLIER LED PSO
5
PSO REQUIREMENTS
REVIEW WITH
PSO TEAM AND
SUPPLIER
3A
SUPPLIER
UPLOADS DOCUMENTS
INTO POWERWAY.COM
6
SUPPLIER PREPARES
DOCUMENTATION AND
CONDUCTS READINESS
EVALUATION RUN
8
SUPPLIER MODIFIES
AND SUBMITS
DOCUMENTATION
AND/OR CONDUCTS
READINESS
EVALUATION RUN
NO
7
PRE-PSO MEETING:
DOCUMENTATION/SRE
ACCEPTABLE?
YES
9
SCHEDULE
PSO ON SITE VISIT
10
SUPPLIER FINALIZES
LINE AND APPROVES
EVIDENCE OF PRODUCTION READINESS
Figure 2.1
PROCESS SIGN-OFF
RESPONSIBILITY
LEGEND
L = LEAD
RESPONSIBILITY
S = SUPPORT TO
P = PROVIDES
INFORMATION
P/S = DEPENDS ON
COMPOSITION OF
PSO TEAM
PROCESS NAME
Part enters
Powerway.com
Initial Risk
2
3&
Supplier led PSO
3(A)
DaimlerChrysler led
4
PSO
PSO Requirements
5
Review
Supplier prepares
6 documentation and
readiness evaluation
Pre-PSO
7 Documentation
Reviews
Supplier modifies and
8 submits
documentation
Schedule PSO On9
Site Visit
Supplier finalizes line
10 and approves
evidence production
DCC
PROCUREMENT
DCC
ENGINEERING
DCC
MANUFACTURING
DCC
ASQP
SUPPLIER
FLOWCHART RESPONSIBILITIES
P/
S
P/
S
REMARK
11
PSO ON-SITE VISIT or
SUPPLIER CONDUCTS
PRODUCTION
DEMONSTRATION RUN
YES
12A
PSO ON-SITE REVISIT
NECESSARY?
NO
12
ELEMENTS 1-20
ACCEPTABLE?
YES
NO
13
SUPPLIER CONDUCTS
CORRECTIVE ACTION
AND SUBMITS
DOCUMENTATION
14
Z DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
15
SUPPLIER CONDUCTS
ELEMENT 21
YES
18
REPETITION
OF ELEMENT 21
SUFFICIENT?
19A
SUPPLIER CONDUCTS
PSO IN ACCORDANCE
WITH PSO MANUAL
AND ENTERS PSO
DATE & DISPOSITION
INTO POWERWAY.COM
NO
17
INVESTIGATE REASON
FOR FAILURE AND ROOT
CAUSE ELIMINATION
16
ELEMENT 21
ACCEPTABLE?
NO
YES
20
SUPPLIER SUBMITS
PPAP WARRANT & ENTERS
PPAP DATE IN
POWERWAY.COM
19
PSO APPROVED,
A DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
Figure 2.2
RESPONSIBILITY
LEGEND
PROCESS NAME
11
PSO On-Site Visit
L = LEAD
12 Acceptance of Elements
RESPONSIBILITY
&12(A) 1-20
S = SUPPORT TO
P = PROVIDES
INFORMATION
Supplier conducts
corrective action and
P/S = DEPENDS
13
submits documentation.
ON
ASQP provides approval
COMPOSITION OF
PSO TEAM
"Z" code entered into
14 Powerway.com. Supplier
enters Dimensional PPAP
& date
Supplier conducts
15
Element 21
Acceptance of Element
16
21
Investigate reason for
17 failure and root cause
elimination
18
Repetition of Element 21
PSO "A" disposition &

date entered into
19 Powerway.com. Supplier
enters Material/
Functional PPAP & date
Supplier conducts PSO
and enters A
19A
disposition & date into
Powerway.com
20
Supplier submits PPAP

warrant and date into
Powerway.com
DCC
PROCUREMENT
DCC
ENGINEERING
DCC
MANUFACTURING
DCC
ASQP
SUPPLIER
PROCESS SIGN-OFF
FLOWCHART RESPONSIBILITIES
P/
S
S P/S L
P/
S
S P/S L
S P/S L
P/
S
S P/S S
P/
S
S P/S L
P/
S
S P/S S
P
P/
S
P
REMARK
Refer to
PPAP
Manual for
further
details
10
PSO ELEMENT REQUIREMENTS
11
PART NUMBER, DESCRIPTION AND CHANGE LEVEL

Element Requirements
Documentation
1.1 The PSO team shall review all PSO related documents to ensure
CATIA files, drawings,
all documents have the correct part number, description and change
Comment page, Part
level present or cross-referenced (see ISO/TS-16949 cl. 4.2.3 Control
Information Pages (PIP)
of Documents).
(including list of
applicable engineering
1.2 A procedure shall be in place to assure correct part number and
standards, software
revision level as changes occur. This procedure shall also ensure
level and hardware
affected documents (e.g. Control Plan, PFMEA, etc.) are updated and
level) (MANDATORY
applicable testing is performed for each change.
ENGLISH)
Gage Dimensioning &
1.2.1 This procedure shall include communication and notification
Tolerancing (GD&T)
of changes throughout the Supply Chain. The Tier 1 Supplier is
sheets (MANDATORY
ultimately responsible to ensure product shipped to DCC (or other
ENGLISH)
designated manufacturing facility) is the latest revision level.
Part number cross
reference sheet (if
1.2.2 This procedure shall include the receipt of an approved DCC
applicable)
Change Notice. The Supplier shall not make any changes
Engineering Change
without DOCUMENT approval from the customer (voicemail, eprocedure
mail, etc. are UNACCEPTABLE).
Document Control
procedure
1.3 Where the product identity is not inherently obvious, the Supplier
shall employ an internal numbering system and provide a cross
reference which enables users to identify the DCC part number and
revision level which corresponds to the Suppliers numbering and
revision system.
1.4 The Supplier shall have a procedure which prevents nonstandardized or out of date documents and instructions from existing
on the manufacturing floor (e.g. Document audit). Refer to ISO/TS16949, cl. 4.2.3 Control of Documents.
Engineering Standards Identified
1.5 A process shall be in place to obtain revisions to all DCC,
governmental, Safety <S>, and other product related standards and
specifications. DCC standards are available via Engineering Standards
Supplier Distribution (ESSD) at
https://essd.extra.daimlerchrysler.com/ESSD/Login.jsp.
1.5.1 This process shall address notification to all applicable
departments of standard changes as they occur. This process shall
also include the frequency and responsibility for reviewing the
standards (not to exceed two working weeks; reference ISO/TS16949, cl. 4.2.3.1 Engineering Specifications.)
1.6 The PSO Team shall verify that the CATIA Comment page or Part
Information Page (PIP) lists all applicable standards, including, but not
limited to, those shown on the source package and signed DVP&R (see
Element 3 Test Sample Sizes and Frequencies.)
1.6.1 DCC approval for all deviations from listed standards shall
be documented on the CATIA Comment page/PIP and DVP&R.
12
PART NUMBER, DESCRIPTION AND CHANGE LEVEL, CONT.

1.6.2 The PSO Team shall verify that the CATIA Comment page or
PIP lists all sub-components of the end-item assembly. This listing
shall include DCC part number (if applicable), Supplier part
number, quantity, and revision level.
1.6.3 The PSO Team shall verify that all dimensional requirements
are defined on the GD&T sheets and attached to the design model.
The Supplier shall consistently apply a mutually agreed upon (with
the DCC PSO Team) datum scheme throughout the part
development process.
13
DESIGN FMEA
2.1 Design FMEAs (DFMEAs) shall be created using the latest AIAG
and DCC guidelines. If AIAG and DCC guidelines disagree, DCC
guidelines take precedence.
Documentation
DFMEA (MANDATORY
ENGLISH)
Best Practice
procedure
2.2 The Supplier shall have an internal best practice procedure that
is utilized in the development of DFMEAs. The procedure shall include
documentation and data which explains how the DFMEA severity,
occurrence, and detection numbers were developed.
2.2.1 This procedure shall be reviewed periodically for effectiveness
and shall include lessons learned with inputs from past issues (e.g.
eCIMS, NCT, warranty, CSA, yard holds, etc.)
2.2.2 The procedure shall include use of the Rolling Top 20 rule
for continuous improvement. This requires the Supplier to Pareto
failure modes and address the top 20% using RPN values
(regardless of actual RPN value.)
2.3 Error proofing and controls shall be identified in the DFMEA.
2.4 The DFMEA is a living document and shall be traceable to all
design changes. It shall contain all special characteristics from
Element 12 Special Product/Process Characteristics Identified.
2.5 A DFMEA shall be completed for each unique Supplier-designed
product. The DCC Product Engineer has the lead responsibility for
ensuring that the DFMEA meets all requirements. Additionally, timely
completion and approval of all DFMEA activities shall be completed on
or before required quality gate timing. Reference the CDS Quality Gate
Book at http://roadmap.tcc.chrysler.com/cds/ for specific timing.
2.6 The DFMEA shall include all sub-components of the end-item
assembly.
2.7 The Supplier shall ensure all failures observed during Engineering
Development (ED) and Design Verification (DV) testing are captured
within the DFMEA.
2.8 The Supplier shall ensure the occurrence and detection ability of
failures observed during DV testing correlate with the occurrence and
detection numbers documented on the DFMEA.
2.9 Buzz-Squeak-Rattle (BSR) and Noise-Vibration-Harshness (NVH)
issues shall be addressed, if applicable.
NOTE: Special attention (as defined by DCC Engineering) shall be
given to failure modes with:
A Severity 8, regardless of Occurrence or Detection values.
A Severity 5 and Occurrence 2, regardless of Detection (this
equates to customer dissatisfaction and cs/1000 > 1.)
A Detection of 10.
See Appendix B FMEA Guidelines.
14
TEST SAMPLE SIZES AND FREQUENCIES

3.1 Products covered under a Performance Standard (PF) that
specifies test sample sizes, test frequencies, and acceptance criteria
shall have testing requirements included in a Design Verification Plan
and Report (DVP&R), including a Test to Failure verification plan.
Reference the Product Assurance Testing manual.
3.2 Design Verification (DV) and Production Validation (PV) test plans
shall be signed by the DCC Product Engineer PRIOR to testing.
3.3 Completed DV and PV test results shall be signed by the DCC
Product Engineer.
3.4 All functional requirements shall be defined in the DVP&R and
verified against applicable Performance Standards for accuracy.
Documentation
DCC Engineering
signed DVP&R
(MANDATORY
ENGLISH)
Applicable Engineering
Standards
(MANDATORY
ENGLISH)
DCC Engineering
signed DV and PV test
plans (MANDATORY
ENGLISH)
Annual Validation
procedure
3.4.1 Deviations from the Performance Standards shall be

identified and visible on the CATIA Comment page or PIP and
DVP&R (e.g. changes to test sample sizes, test waivers, etc.) See
Element 1 Part Number, Description, and Change Level.
3.4.2 Continuous Conformance testing shall be documented on
the DVP&R when applicable.
3.4.3 A "circle grid analysis", or other formability analysis, is
required for PSO approval on stamped components if required by
the DCC ASQP Specialist and/or Engineer.
3.4.4 DCC internal stamped components shall follow the
requirements in MQAS 90-6710 Dimensional Buy-Off Procedure
for Upgrading Stamped Parts During Die/Tool Development.
3.5 All testing failures shall be documented on the DVP&R and
addressed with a DCC 8-Step Corrective Action plan (available on the
Forever Requirements webpage and through COVISINT).
3.6 Annual validation testing shall be completed each model year as
specified in the Product Assurance Testing manual and applicable
Performance Standards, unless waived in writing by the DCC Product
Engineer and ASQP Specialist. Reference ISO/TS-16949, cl. 7.5.2.
NOTE: A written waiver is required each model year that annual
validation will not be performed.
3.6.1 The Supplier shall have a procedure to ensure on-time
Annual Validation, prevent scheduling conflicts and fixture/testing
shortages in the event of multiple Annual Validations.
15
PROCESS FMEA
4.1 Process FMEAs (PFMEAs) shall be created using the latest AIAG
and DCC guidelines. If AIAG and DCC guidelines disagree, DCC
guidelines take precedence.
4.2 The Supplier shall have an internal best practice procedure that
is utilized in the development of PFMEAs. The process shall include
documentation and data which explains how the PFMEA severity,
occurrence, and detection numbers were developed.
Documentation
PFMEA (MANDATORY
ENGLISH)
PFMEA Audit
Summary
(MANDATORY
ENGLISH)
Best Practice
procedure
4.2.1 This procedure shall be reviewed periodically for effectiveness

and shall include lessons learned with inputs from past issues (e.g.
eCIMS, NCT, warranty, CSA, yard holds, etc.).
4.2.2 The procedure shall include use of the Rolling Top 20 rule
for continuous improvement. This requires the Supplier to Pareto
failure modes and address the top 20% using RPN values
(regardless of actual RPN value.)
4.3 Mistake proofing and controls shall be identified in the PFMEA.
4.4 The PFMEA is a living document and shall be traceable to all
process changes. It shall contain all special characteristics from
Element 12 Special Product/Process Characteristics Identified.
4.5 The DCC ASQP Specialist has the lead responsibility for ensuring
that the PFMEA meets all requirements (green) per the Supplier
PFMEA Audit Summary sheet. Also, timely completion and approval
of all PFMEA activities shall be completed on or before required quality
gate timing. Reference the CDS Quality Gate Book at
http://roadmap.tcc.chrysler.com/cds/for specific gate deliverables.
4.6 The PFMEA shall reflect the entire manufacturing process from
receiving through shipping.
4.7 The Supplier shall ensure that all failure modes observed during
all pre-production runs are captured on the PFMEA.
4.7.1 The Supplier shall ensure the rate of occurrence and ability
to detect failures observed during pre-production runs correlate
with occurrence and detection numbers documented on the FMEA.
4.8 BSR and NVH issues shall be addressed if applicable.
NOTE: Special attention shall be given to failure modes with:
A Severity 8, regardless of Occurrence or Detection values.
A Severity 5 and Occurrence 2, regardless of Detection value
(this equates to customer dissatisfaction and cs/1000 > 1.)
A Detection of 10.
See Appendix B and the Supplier PFMEA Audit Summary sheet
(internal DCC work instruction PSWI-1047; Suppliers do not have
access and should obtain a copy from their ASQP Specialist.)
16
PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN

Documentation
5.1 The process flow diagram shall represent the entire
Process flow diagram
manufacturing process from receiving through shipping
(or equivalent)
operations, including main-line assembly processes as well as all off(MANDATORY
line supply processes.
ENGLISH)
Manufacturing floor
5.1.1 The process flow diagram shall include the processing
plan
sequence, method and equipment used at each station (including
Work Station Layout
inspection and repair/rework stations).
5.1.2 Stations which measure special characteristics and/or
contribute to significant customer issues shall be identified.
5.2 The manufacturing floor plan shall show the layout of the facility
and the station-by-station flow of the manufacturing process.
5.2.1 The manufacturing floor plan shall highlight all production
equipment used.
5.2.2 The manufacturing floor plan shall show Work in Process
(WIP), raw material, and scrap material storage locations.
5.2.3 A work station layout shall exist which identifies all work
stations.
5.3 The flow diagram, manufacturing floor plan and/or the work
station layout shall include each unique machine number.
station layout shall include the number of operators, including float
operators, required per station (including repair/rework stations). The
PSO team shall verify the number of operators during the On-Site
Visit.
station layout shall identify bottleneck operations or stations.
5.6 All production equipment appearing on the manufacturing floor
plan, flow diagram, and work station layout shall be verified by the
PSO team.
17
CONTROL PLAN & PROCESS MONITORING

6.1 The Control Plan shall describe each step of the manufacturing
process including: receiving, material handling and storage, inprocess operations, testing, inspections, rework/repair, shipping,
temporary or interim off-standard operations (e.g. back-up
operations), and continuous conformance. Refer to the AIAG
Advanced Product Quality Planning manual.
6.1.1 Measurement and inspection frequencies detailed in the
Control Plan, including all inspections for appearance
requirements, shall be verified by the PSO Team during the
Production Demonstration Run.
Documentation
Control Plan
(MANDATORY
ENGLISH)
1st piece approval
procedure & records
Control Charts
Process Performance
Log Sheets
Defect Tracking Sheets
6.1.2 Repair/rework stations shall have controls equivalent to

those of the primary production line.
6.1.3 The Control Plan shall address verification of Mistake
Proofing (e.g. number of pieces, frequency, etc.).
6.1.4 The Supplier shall have a process which links the Suppliers
DFMEA and PFMEA to the Control Plan. This process shall ensure
that controls, lessons learned, etc. detailed in the DFMEA and
PFMEA, are carried forward into the Control Plan.
6.1.5 The Supplier shall reference known issues from similar
products (e.g., e-CIMS, warranty, NCTs, yard holds) and include
any applicable preventive actions in the Control Plan.
6.1.6 All process and product control parameters and tolerances
shall be documented in the Control Plan.
6.1.7 All special characteristics identified in the GD&T sheets
and the DVP&R and any special characteristics that describe
materials, processes, performance, reliability, quality, and/or
design requirements identified in the DFMEA and PFMEA shall be
included in the Control Plan.
6.1.8 Sample sizes shall be based on industry-standard statistical
sampling plan tables or shall use Statistical Process Control (SPC).
Process Monitoring
6.2 The Supplier is responsible for maintaining manufacturing
process capability and shall have a procedure requiring documented
corrective actions for all out of control measurements. All reaction
plans shall include containment of suspected non-conforming product
and 100% inspection as approved by the PSO Team.
6.3 A documented First Piece Approval procedure shall exist which
verifies product at each station is being made according to
specification, proper machine set-up, and correct parameter setting.
18
CONTROL PLAN & PROCESS MONITORING, CONT.

6.3.1 The procedure shall require First Piece Approval at the
beginning of each shift or production run and after any changes
are made to the production process (e.g. tooling modifications, SPC
adjustments, etc.)
6.3.2 The process shall include the retention of the first piece until
the end of the production run or shift and identification of the first
piece sample(s) and analysis of special characteristics identified by
the PSO Team and the Supplier during the AQP process.
6.3.3 Documented evidence of First Piece Approval process
execution shall be maintained. The Supplier shall record the part
number, manufacturing date, and any additional information as
required by the PSO Team.
6.4 All inspection stations shall have a method of defect tracking (e.g.,
tally sheets, scrap sheets, etc.)
6.5 Visual displays of process performance (e.g. FTC, scrap and
rework) and total production maintenance (e.g. downtime, etc) shall be
present on the manufacturing floor and reflect current quality data.
6.5.1 Targets shall be identified for each measurable with
documented plans for achieving those targets.
6.6 Where SPC methods are used, the Supplier is required to maintain
a history of component production sequence, production line,
production tool and characteristics values to assist in assembly plant,
warranty and field return root cause investigations. See the
DaimlerChrysler Customer-Specific Requirements for ISO/TS-16949,
cl. 4.1.1.
6.7 Suppliers shall have a Craftsmanship Quality Initiative Procedure
for all components with appearance requirements. This procedure
shall include: team members, regular scheduled Craftsmanship
reviews and audits, condition resolution tracking matrix, retention of
an Appearance Manual, and containment procedures and guidelines.
6.7.1 Suppliers shall have an Appearance Manual for all
components with appearance requirements. This manual shall
include: appropriate documentation (sign-off sheet, table of
contents, revision history, general appearance characteristics
acceptance specification), studio quality photos of product shown
in appropriate views, studio quality photos for any conditions
deviating from design intent, and all Craftsmanship worksheets
(photos of conditions, containment and permanent correction
actions, along with supporting documentation.)
19
QUALITY PLANNING
7.1 All Advance Product Quality Plans (APQPs) shall coordinate with
DCC Chrysler Development System (CDS) timing for each applicable
program. The plan shall identify major milestone events, required
product or process deliverables, responsible organizations, as well as
scheduled and actual timing dates. Reference the AIAG Advanced
Product Quality Planning and Control Plan (APQP) manual and CDS at
http://roadmap.tcc.chrysler.com/cds/.
Supply Base Management
7.2 The Supplier shall cascade quality planning throughout all subtiers (see cl.7.4.3 of ISO/TS-16949, Quality Management Systems).
7.2.1 The plan shall include an Easy Map diagram. This diagram
should outline the entire Supply Chain, beginning with raw
materials and ending with the DCC or the DCC-designated
manufacturing facility. All secondary processes and/or services
(e.g. plating, heat treating, etc.) shall be shown, including off-site
storage or shipping locations. Easy Map can be found on the
COVISINT website.
7.2.2 Each component listed on the Bill of Material corresponding
to the DCC part number shall have an Initial Risk Evaluation (or
equivalent) performed. The criteria for risking components shall
take into consideration the DCC risk drivers. DCC risk drivers are
found on the Initial Risk Evaluation document in Powerway.com.
Documentation
AQP or APQP
timeline/plan
List with PPAP status
of all sub-components.
Easy Map Supply
Chain diagram
Listed risk of all subcomponents and subtier processes.
Level 3 PPAP
documentation for all
sub-components and
sub-tier processes
risked medium or
high.
DOE (Design of
Experiments)
Copies of eCIMS or 8Step Corrective Actions
for issues encountered
in previous pilot
builds.
Lessons Learned
Communication
procedure
7.2.2.1 Each sub-component determined to be medium or

high risk (or equivalent) shall be accompanied by a PSO (or
equivalent process) conducted by the Supplier. Level 3 PPAP
documentation is also required. Additional documentation may
be requested by the DCC ASQP Specialist.
7.2.3 The Supplier shall have a process which monitors and
documents the quality of all sub-tiers.
Problem Solving
7.3 The Supplier shall have a procedure to convey lessons learned and
corrective actions back through their facility, and all other facilities
within the same company. (Reference ISO/TS-16949, cl. 8.5.2.1
Problem Solving.)
7.3.1 Corrective action shall be implemented across
the entire manufacturing plant for every applicable DCC
production line.
7.4 The acceptable methods for documenting root cause analyses and
corrective actions (for all non-conformances, test failures, etc.) are
through the DCC eCIMS system and/or the 8-Step Corrective Action
form.
20
QUALITY PLANNING, CONT.

7.5 The PSO team shall review corrective actions for any nonconformances or test failures encountered prior to the PSO visit (e.g.
during pilot builds, DV testing, etc.) The team shall ensure that all
corrective actions have been completed and implemented (e.g. through
error and/or mistake proofing, process or design changes, etc.)
7.6 The Supplier shall have a procedure for conducting Design of
Experiments (DOE). DOE (or similar activities) shall be conducted to
identify and establish the optimal process parameters for all new and
modified parts prior to the PSO On-Site Visit.
7.7 The Supplier shall support all DCC systems (e.g. eCIMS, NonConformance Ticket (NCT) system, Powerway.com, PRAS, COVISINT,
etc.)
NOTE: For source packages that reflect proprietary document
exclusions, those documents sited for exclusion are not required to be
uploaded into Powerway.com. However, these documents shall be
available for review at the request of the DCC ASQP Specialist. A cover
page with the documents title block, revision level and date is required
to be uploaded in place of the actual document.
7.7.1 The Supplier shall have at least 2 individuals with valid
SIDs and passwords for each applicable DCC eSystem (e.g.
Powerway.com, Non-Conformance Ticket system, eCIMS,
COVISINT, PRAS, etc.) All individuals shall be fully trained in
the use of each system for which they access.
7.8 The Supplier shall provide both a Plant and Warranty Quality
Representative, as required, to assist DCC personnel throughout the
life of the program.
7.8.1 Contact names shall be provided by the Supplier upon
request. Additional contact information may be obtained by DCC
personnel (only) through the ODIMS system via the p12 screen.
7.8.2 When the Supplier is a DCC directed sub-tier, the Supplier
Representative(s) shall support the Tier 1 in the same manner as
they would DCC. Support is to begin at Gate G1 Theme Selection
and continue though the life of the program.
7.9 Design responsible Suppliers are responsible for Design for
Serviceability, which ensures ease of disassembly of product with
minimal cost and time.
21
INCOMING & OUTGOING MATERIAL QUALIFACTION/CERTIFICATION PLAN

Documentation
Incoming Material Certification Plan
Incoming inspection
8.1 The Incoming Material Certification Plan shall include procedures
plan
used to qualify and certify incoming material prior to releasing into
Sampling plans
production.
Receiving Reports
Inspection/test reports
8.2 The plan shall have a product validation procedure which
Copies of sub-tier
determines the frequency of inspection based on component and subSupplier Certificates of
tier history.
Analysis for each
specific sub8.2.1 The plan shall include an escalation process which
component
increases the inspection frequency when a defect is found.
Copies of sub-tier
Supplier PSWs (Part
8.2.2 When the plan includes dock to stock (i.e. ships parts
Submission Warrant)
directly out of the receiving area without inspection) the process, at
Copies of sub-tier
a minimum, shall require three previous consecutive shipments to
Supplier ISO-9001
have been defect-free and without subsequent internal or external
certifications
non-conformances.
Outgoing Inspection
Plan
8.3 The plan shall include incoming acceptance sampling plans, for
Part Inspection
both attribute and variable data. Two or more of the methods
Standard
described in cl. 7.4.3.1 of ISO/TS-16949 shall be used; otherwise, the
Audit Work
minimum requirements found in the Lot Acceptance Sampling Table
Instructions
(see Appendix B) apply. Inspection frequencies and sampling plans
Shipping
reports
shall be documented in the Control Plan. Lot size shall not exceed one
Audit
Records
shift or one production run, whichever is smaller.
NOTE: The requirements in the Lot Acceptance Sampling Table are for
attribute sampling only. SPC is superior and if used, the sampling
quantities in the Lot Acceptance Sampling Table need not be followed.
8.4 The plan shall identify all processes performed by sub-tiers (e.g.
plating, heat-treating, etc.) and include records indicating
inspection/test results that relate to the appropriate lot code.
8.5 The lot acceptance date (or date the lot was inspected) shall
include the year, month, day and numeric sequence.
8.6 Components or production materials used in the assembly of parts
for DCC shall have full PPAP (or equivalent). The PSW for each subcomponent in the end-item assembly shall be easily accessible.
8.7 Certificates of Analysis shall comply with DCC Engineering
Standards identified on the CATIA Comment page or PIP.
8.8 The Supplier shall have copies of their sub-tiers ISO 9001
certification on file.
22
INCOMING & OUTGOING MATERIAL QUALIFACTION/CERTIFICATION PLAN, CONT.

Outgoing Material Inspection Plan
8.9 The Outgoing Material Inspection Plan shall include procedures
used by outgoing inspection to qualify outgoing product prior to
shipment to the customer.
8.10 The plan shall include outgoing acceptance sampling plans, for
both attribute and variable data. Inspection frequencies and sampling
plans shall be documented in the Control Plan.
8.11 Components or modules that have been designated as key shall
have a Part Inspection Standard completed. Reference DCC internal
procedures PSSP0301 Part Inspection Standard for specific
instructions on completing the Part Inspection Standard and
PSSP0600 Key Component Designation for Supplier Quality.
Suppliers do not have access to these procedures and should contact
their ASQP Specialist for further information. The Part Inspection
Standard form is available on-line through COVISINT.
8.12 The lot acceptance date (or date the lot was inspected) shall be
identified by the year, month, day and numeric sequence.
8.13 Certificates of Analysis, if required by DCC for the finished
product, shall comply with DCC Engineering Standards identified on
the CATIA comments page or PIP.
8.14 Shipping, Audit, and Containment Records shall be documented
and maintained.
23
PARTS HANDLING PLAN

9.1 The Parts Handling Plan shall include procedures that detail all
internal material handling operations.
9.2 The plan shall describe the types of containers used throughout
the internal manufacturing process (including any external processing
such as heat treating, plating, etc.) Each container type shall be
clearly defined with material dimensions, quantity per container, part
numbers, stack height limits (static & mobile), weight, ergonomic
requirements, etc.
Documentation
Parts Handling Plan
Material handling
procedures
Containment Records
NOTE: Container information may be included as a part of the

Packaging Instructions. See Element 10 Operating Instructions.
9.3 A method shall exist to clearly identify and differentiate
rework/repair, scrap, WIP bins, etc.
NOTE: DaimlerChrysler does not procure returnable containers for
Suppliers WIP (Work in Process) or sub-tier Suppliers. Containers for
these components are the responsibility of the Supplier. Use of DCC
containers for this purpose is considered misappropriation of DCC
corporate assets and is unacceptable. If the PSO Team detects a
container violation during the PSO On-Site Visit, Element 9 Parts
Handling Plan on the PSO SUMMARY REPORT shall be marked
REJECT in the Process column and an explanation added to the
COMMENTS SHEET.
9.4 The plan shall include the procedures for in-process raw material
re-stock (e.g. Kan- Ban) and inventory control (e.g. FIFO).
9.4.1 Material storage locations shall be clearly identified.
9.4.2 When FIFO is used as a method of inventory control, the
Supplier shall have an effective method of ensuring FIFO stock
rotation throughout the manufacturing facility
9.4.2.1 When the traceability process is FIFO-dependent, the
Suppliers shipping process and all sub-tiers shall conform to
FIFO.
9.5 The plan shall have a procedure by which material is tracked and
transferred from one process to another (e.g. travelers, routing cards,
etc.)
9.5.1 Information shall include lot number, date, number of pieces
entering/exiting the operation, number of pieces
reworked/repaired, number of pieces scrapped, operation number
and shift.
9.6 All parts shall have lot control and traceability, throughout all
stages of production (and shipping, if applicable), and be documented
and verified (cl. 7.5.3 & 7.5.3.1 of ISO/TS-16949.) Lot size shall not
exceed one shift or one production run, whichever is smaller.
24
PARTS HANDLING PLAN, CONT.

9.6.1 Sorted, reworked or repaired material shall be traceable back
to the sort, rework or repair process.
9.7 The plan shall address containment of non-conforming material.
This shall also include the use of the DaimlerChrysler Supplier
Notification of Potential Nonconformance process outlined in the
Forever Requirements located on the COVISINT website.
9.7.1 The plan shall address part handling and part identification
for nonconforming product, from receiving of returned material
back from the customer to final disposition.
9.7.2 The plan shall detail the maximum amount of time allowed
for disposition of quarantined product.
9.7.3 The Supplier shall have a locked and/or controlled area for
holding non-conforming, quarantined, or non-production product
(e.g. engineering samples.) Product in the holding area shall be
clearly identified with part number, number of pieces, date
quarantined, reason for quarantine, and expected disposition date.
Electro-Static Discharge (ESD) Guidelines
9.8 Any manufacturing facility handling components that must be
protected from ESD shall have the following:
ESD mats and/or floors;
Heel and/or wrist straps (ESD certified shoes are also
acceptable;)
ESD testers for operators to verify heel and wrist straps, and/or
shoe effectiveness. All ESD testers shall have up-to-date operator
instructions and be included in the calibration procedures and
schedule, as well as the Preventive Maintenance plan;
Clearly-identified ESD containers (e.g. bags, totes, etc.) for ESD
sensitive product to be transported to and from the line, and inprocess;
ESD workbenches that are grounded with plugs for wrist straps
(if applicable);
ESD gloves and/or finger cots for handling of PCB's (e.g. rejects.)
9.8.1 All ESD operators shall be properly trained and be identified
in some way (e.g. badges, buttons, etc.)
9.8.2 Work instructions for ESD testers shall mandate testing of
everyone as they enter the ESD production floor.
9.8.3 An ESD certification schedule shall exist which mandates
recertification of all ESD equipment, tools, testers, containers, and
personnel on an annual basis (minimum.) Records of the
certification and the recorded measurements shall be kept.
9.8.4 The ESD manufacturing process shall be included in the
Suppliers Layered Process Audit plan.
25
OPERATING INSTRUCTIONS
10.1 Operator, set-up, changeover, 1st piece approval, mistake
proofing, rework/repair, gage operating, inspection and packaging
instructions shall be approved and signed by the appropriate Supplier
departments (e.g. Quality, Engineering, Manufacturing, etc.) They
shall be dated and traceable to the level of parts being produced, and
shall include sample sizes and frequencies.
10.1.1 Special characteristics shall be identified in the appropriate
instructions.
10.1.2 All instructions shall enable any adequately trained person
to perform the described operation.
Documentation
Operator instructions
Set up sheets
Inspection instructions
1st piece approval
instructions
Mistake proofing
instructions
Rework/repair
instructions
Operator Qualification
process
Gage instructions
10.2 The Supplier shall have a process for training and qualifying
operators prior to operators performing production processes (e.g.
classes, mentorship, temporary supervision, etc.). Operator training
shall be documented and maintained.
10.2.1 A list of training requirements for each unique workstation
shall be maintained.
10.2.2 Visual inspection stations shall have methods established
to verify the operators ability to find defects (e.g. periodic testing,
recertification, etc.)
10.2.3 Operations requiring special certification shall be identified
and operators certified to perform that operation shall be identified
(e.g. rework/repair.)
10.3 All instructions, control charts, defect tracking sheets, log
sheets, and reactions shall be located adjacent to the process, visible
to the operator and legible (reference TS-16949, cl. 7.5.1.2 Work
Instructions.) Visual management techniques (e.g. displays, pictures,
diagrams, etc.) shall be used whenever possible.
10.3.1 Sample parts used as visual displays shall be identified and
maintained to the correct revision level. The Supplier shall also
have a procedure which periodically verifies the condition of
designated conforming Boundary samples to ensure the samples
are still acceptable.
Rework and Repair Instructions and Procedures
10.4 The DCC PSO team shall approve all rework and repair
operations, procedures and work instructions.
10.4.1 All reworked/repaired products shall be clearly and
uniquely identified. See Element 9 Parts Handling Plan.
26
OPERATING INSTRUCTIONS, CONT.

10.4.2 The rework/repair procedure and instructions shall state
that when a sub-component is replaced which has Safety <S>
characteristics and a new sub-component is installed, the lot from
which the replacement sub-component came shall be identified
and it shall be linked one-to-one with the final assembly or lot on
which the sub-component was used.
10.4.3 The rework/repair procedure and instructions shall state
that when a sub-component is removed from an assembly which
has been returned from a DCC facility which is to be re-used in
another assembly, the lot code of all sub-components with Safety
<S> characteristics shall be identified and linked one-to-one with
the new assembly or lot in which the component will be used.
10.4.4 The rework/repair procedure and instructions shall require
traceability and/or part identification in the event that any part
returned from a DCC assembly plant is to be re-sent without
rework or performed (e.g. parts sorted as good from a returned,
quarantined lot.)
27
TOOLING, EQUIPMENT, AND GAGES IDENTIFIED

Documentation
11.1 The Supplier shall establish a tooling list which includes all
Tooling list
production, interim, and/or temporary tooling and equipment used in
Supplier Tool Record
the production process.
(STR)
11.1.1 The list shall indicate ownership (e.g. Supplier owned, other
OEM, etc.) for each item listed.
11.2 All DCC owned tooling, fixtures, and gages shall be clearly and
permanently marked with the same tool number as identified on the
Supplier Tool Record (STR) and the Tool Purchase Order, and be
identified Property of DaimlerChrysler. The method used to mark the
tools shall be non-degradable and fireproof (paint, ink, paper tags, etc.
are unacceptable methods of marking.) All tooling, equipment, gages
and fixtures shall possess unique identification numbers. Reference
ISO/TS-16949 cl. 7.5.4 Customer Property and the DCC Purchase
Order. The STR can be obtained from the DCC Buyer.
11.2.1 Gages shall be manufactured and approved per the
DCC gage standards identified on the Advance Manufacturing
Engineering (AME) website http://ame.ctc.chrysler.com/gages.
11.2.2 Verification of the STR against the Suppliers
manufacturing facility shall be performed by the PSO team during
the PSO On-Site Visit. In the event tooling, gages and/or fixtures
reside at the Suppliers sub-tier, the sub-tier location shall be
indicated on the STR.
NOTE: DaimlerChrysler owned tooling shall be used for the
production of DaimlerChrysler product(s) only.
11.3 All tooling, fixtures, equipment and gages used in the
manufacturing process (e.g. from the laboratory, production, tool
room, maintenance, quality, etc.) shall be identified in the Suppliers
maintenance, storage, and calibration procedures.
28
SPECIAL PRODUCT & PROCESS CHARACTERISTICS IDENTIFIED AND FPSC

Documentation
12.1 A list of special characteristics shall be developed using DCC
List of special
input as well as Supplier knowledge of the product. Special
characteristics
characteristics are product characteristics or manufacturing process
PPSR (Pre-Production
parameters which can affect safety or compliance with regulations, fit,
Sample Report)
function, performance or subsequent processing of product. They
(MANDATORY
include all governmental, Key (diamond) <D>, and Shield (safety <S>
ENGLISH DOC)
and emissions <E>) characteristics. Torque requirements and
FPSC (First
characteristics identified as SPC points on the design model shall also
Production Shipment
be considered special characteristics. Other characteristics deemed
Certification)
critical to the process or end-item assembly may also be designated as
(MANDATORY
special characteristics by the Supplier and/or PSO Team. Reference
ENGLISH DOC)
the AIAG PPAP (4th ed.) manual and cl. 4.2.1.3, 4.2.1.4, and 4.2.1.5 of
the DCC Customer-Specific Requirements for ISO/TS-16949.
12.1.1 All special characteristics shall be noted on all applicable
quality documents (e.g. Control Plan, DFMEA, PFMEA, DVP&R,
and set-up and operator instruction sheets).
12.1.2 The Supplier shall have documented definitions of internal
special characteristics and the requirements for selection, control
and monitoring of them.
12.2. All special characteristics shall be included in the
MEASUREMENT SYSTEM REPORT and the INITIAL PROCESS STUDY.
See Element 15 Evidence of Product Specifications and Element 20
Initial Process Study.
12.3 For special characteristics not identified as Safety (<S>)
characteristics or SPC points on the design model, SPC is not required
unless specified by the PSO team.
Safety Characteristics
12.4 A system shall be established and maintained to track Safety
(<S>) related activities including a listing of all Safety (<S>)
characteristics (also referred to as a Master Tracking List). This list is
used to provide overall Safety related coordination and to assist in
developing primary and secondary measurements. Engineering
Standards shall be shown or referenced on affected procedures and
work instructions for processing and verification during production.
12.4.1 The Supplier shall use SPC reporting for all Safety (<S>)
characteristics that shall be made available to DCC representatives
upon request. Refer to PF-SAFETY for additional requirements and
information regarding Safety (<S>) characteristics.
12.4.1.1 Each Safety (<S>) designation shall have both a
(100%) primary measurement process and a secondary QC
Audit measurement process designed to maintain lot control.
12.4.1.1.1 The primary measurement is performed by
production operators or skilled trades / Manufacturing
Engineering (ME) personnel for robotics, equipment, dies,
fixtures, tools, gages, etc. as determined locally.
29
SPECIAL PRODUCT & PROCESS CHARACTERISTICS IDENTIFIED AND FPSC, CONT.

12.4.1.1.2 The secondary measurements (QC Audit) shall
have Quality Auditors performing visual and/or physical
checks at specific sample sizes and frequencies and
recording results on statistical charts.
12.4.1.1.3 The acceptable checking method, sample size
and sample frequency for establishing lot control within the
Suppliers facility shall be determined by the Suppliers
Control Plan and/or as directed by DCC.
12.4.2 A process shall be in place and maintained which tracks
any non-conformances related to a Safety (<S>) characteristic
including proper corrective action notification, implementation
verification, and carrying forward lessons learned (to be included in
FMEAs, control plans, existing and future DCC programs, etc.)
12.4.2.1 Detection of any non-conformance during sample
verifications shall result in the immediate quarantine of all
product, with disposition determined by the PSO Team.
12.4.3 Periodic system audits related to Safety characteristics
shall be performed as a part of the overall control plan OR as
specified by DCC. In addition, DCC may perform audits and/or
elect to have a third party audit completed.
First Production Shipment Certification (FPSC) Plan
12.5 The FPSC plan requires the Supplier to provide statistical
evidence of conformance to special characteristics. Certification is for
a minimum of the first 2000 parts shipped to each DCC or other
designated plant, or a specified time period as identified by the DCC
PSO team, from each Supplier production line and cavity. 100% of the
FPSC parts are to be inspected for conformance to special
characteristic requirements. The FPSC quantity may be adjusted by
the DCC PSO team based on such factors as low production volumes,
etc. Reference the internal DCC procedure PSSP0106 First
Production Shipment Certification (FPSC). Suppliers do not have
access to this procedure and should contact their DCC ASQP
Specialist for additional information.
12.5.1 The Supplier shall provide the FPSC plan for PSO team
approval at the Pre-PSO meeting.
12.5.2 All parts and components, regardless of risk or AQP activity
level, shall meet FPSC requirements.
12.5.3 All completed FPSCs for Collaborative and Directed AQP
activity level programs shall be reviewed with the DCC PSO team.
30
ERROR AND MISTAKE PROOFING

13.1 The Error and Mistake Proofing Plan shall describe how the
Supplier addresses error proofing and mistake proofing from an
organizational level.
NOTE: Error proofing eliminates, by design, the possibility of
producing a specific defect. Mistake proofing identifies errors in
production and prevents them from becoming non-conformances.
13.1.1 The plan shall include the creation of Verification Samples
for verification of mistake proofing. These shall include all failure
modes identified in the DFMEA and PFMEA.
Documentation
Error and Mistake
Proofing Plan
List of error and
mistake proofing
implemented by
operation number
Error and Mistake
Proofing studies
Mistake Proofing
Contingency Plan
13.1.2 Verification Samples shall be verified on the production line

as frequently as needed to ensure mistake proofing is operational.
Frequency of verification shall take into account start of shift,
production changeover, major disruptions, tooling maintenance,
etc. Verification shall occur once per shift or per production
changeover (whichever is more frequent) at minimum. See Element
14 Layered Process Audit Plan, cl. 14.7.2 and the DCC CustomerSpecific Requirements for ISO/TS-16949 cl. 4.2.9.1.
NOTE: It is strongly recommended that error and mistake proofing
verification also occur whenever the production line experiences an
unplanned disruption and/or down-time.
13.1.3 All Verification Samples shall be clearly marked, labeled
and controlled to prevent mixing with production materials. They
shall be stored separate from WIP or finished product in a clearly
marked container or designated area.
13.1.4 Error and Mistake Proofing software shall be tested for all
possible failures and bypass scenarios.
13.2 Line or station lock out shall be implemented in the
manufacturing process at all steps to prevent failed operations from
proceeding to a subsequent station or into finished product. Audible
and visual indicators shall notify of the failed operation.
13.2.1 A contingency plan shall be documented in the event the
production mistake proofing is not operable. A visual and/or
audible alert shall signify the mistake proofing is inoperable. The
plan shall include notification of the DCC ASQP Specialist per the
Forever Requirements.
13.3 Error and/or mistake proofing shall exist for all failure modes
with severity of 8 and higher in the PFMEA and DFMEA.
13.4 Error and/or mistake proofing shall be used on all special
characteristics.
13.5 All reworked or repaired product shall pass through error and
mistake proofing equivalent to that on the primary production line.
31
ERROR AND MISTAKE PROOFING, CONT.

13.6 Error and mistake proofing verification shall be addressed in the
Preventive Maintenance Plan.
13.7 Sequential sensing shall be used when the process utilizes
physically independent cells making up one process flow.
13.8 Any station used as a final verification (e.g. end-of-line (EOL)
tester, vision station, etc.) shall leave a unique, identifiable mark
indicating that the part has successfully passed through the entire
process. Error and/or mistake proofing shall ensure that parts cannot
skip this operation.
13.8.1 Mistake proofing shall verify that the end-item assembly is
complete with correct content.
NOTE: Verifying that the component is in the machine prior to
assembly, and then assuming it is on the finished product after the
machine cycle is not acceptable.
13.9 All functions, efforts and travel shall be exercised and measured
100% on line to their full extent.
13.10 All sub-components, which are sorted for specific application
(content or function), shall have 100% verification of proper part
selection through error and/or mistake proofing.
13.11 All cylinders applying components or performing staking shall
be verified for full stroke.
13.12 Manufacturing processes (e.g. Injection Molding, Welding, Heat
staking, etc.) shall have controllers (e.g. RJG, MACO etc.) with closed
loop feedback systems and process limits established.
13.13 All critical lubrication, adhesive points, liquids and gases shall
be automated and have error and mistake proofing for proper flow,
amount, and location.
13.13.1 Leak testing for liquids and gas shall be automated
and measured 100% on line.
13.14 Assembly machines that accommodate right and left parts in
the same process shall have error and/or mistake proofing to prevent
assembly and packing errors.
NOTE: The process flow shall accommodate separate paths of right
and left parts if deemed necessary by the PSO team.
13.15 The Supplier shall have error and/or mistake proofing to
prevent loose foreign objects in assembly.
32
ERROR AND MISTAKE PROOFING, CONT.

Requirements for Electrical Components
13.16 All electrical connections shall have a positive detent that can
be identified through audio, tactile or visual feedback.
13.17 All electrical components and connections shall have continuity
and functional check with automated line stop/lockout if continuity is
not achieved to verify integrity of the connection.
13.18 When making terminal contact for in-process manufacturing
(harness assembly, engine testing, device testing, etc.) the following
requirements shall be followed:
Pogo pins shall not violate the contact area of the terminal(s)
being tested;
Pogo pins shall be maintained and inspected regularly;
The test fixture shall provide features to align the connector to
the test fixture prior to engagement of the pogo pins;
When pogo pin access is not provided and spring member
contact is the only option, the probe used to contact the terminal
spring member shall be smaller in thickness than the minimum
blade thickness (including tolerances) of the terminal being
tested. If round pin terminals are being tested, the male pin
probe shall be smaller than the minimum diameter (including
tolerances) of the pin;
The depth of insertion of the probe shall be the minimum depth
required to make electrical contact for testing.
Requirements for Modules/Sequenced Part Delivery (SPD)
13.19 Barcodes and/or pick lights with break beams (or equivalent)
shall be used to ensure the correct part is picked and assembled per
the broadcast.
13.20 Vision systems or color sensing shall ensure correct color
match of components, and correct components (where applicable).
13.21 Push click pull method shall be utilized for all electrical and
other applicable connections.
13.22 SPD part sequence shall be maintained throughout the entire
process, including rework and repair.
13.23 The Supplier shall have redundant systems to ensure receipt of
broadcast.
13.24 Components with Safety <S> characteristics shall be traceable
to the VIN sequence.
13.25 An assembly requiring rebroadcast due to a non-repairable
condition shall have additional tracking to maintain sequence and
timely delivery.
33
LAYERED PROCESS AUDIT PLAN

14.1 Layered Process Audit (LPA) is a system of audits performed by
multiple levels of management per the Suppliers organization chart.
Special characteristics (and other characteristics designated by the
Supplier and/or PSO Team) are audited to verify process conformance.
The purpose of LPA is to ensure continuous conformance thereby
improving process stability and first-time capability. Reference the
DCC Customer-Specific Requirements for ISO/TS-16949 cl. 4.2.9.1
and the LPA Fundamentals course (available through TEDS) for
additional LPA requirements.
Documentation
LPA procedures
LPA work instructions
LPA Structure and
Frequency Chart
LPA Process Control
Audit Checklist
LPA Error Proofing
Verification Audit
Checklist
14.2 The LPA plan shall have procedures and work instructions for
each level of management which details their roles and
responsibilities. The plan shall also address handling of nonconformances discovered during the audit and include a detailed
schedule frequency and structure chart.
14.3 The LPA plan shall require top management reviews of LPA
results. It shall state the frequency of management reviews and
require documented meeting minutes and/or open issues.
14.4 The Supplier shall complete a Process Control Audit Checklist
and an Error and Mistake Proofing Verification Audit Checklist.
Examples of each can be found in the LPA course training manual.
14.4.1 The Process Control Audit shall be done once per shift (or
as agreed to by the PSO Team) by a group leader, supervisor, etc.
Management audits shall be done weekly. Manufacturing areas
shall be divided and auditors rotated so that all areas are included.
14.4.2 The Error and Mistake Proofing Verification Audit shall be
done once per shift or product change-over (whichever comes first)
and whenever an unscheduled disruption occurs in the production
line. The audit must be performed by qualified, trained personnel
only. Reference Element 13 Error and Mistake Proofing cl. 13.1.3.
14.4.3 After PSO approval, no item shall be removed from the LPA
checklists without the DCC ASQP Specialists approval regardless
of initial AQP Activity Level.
14.4.4 All non-conformances discovered at DCC manufacturing
facilities (at any program stage) shall be included in the LPA.
14.5 The Supplier shall demonstrate at least one level of an LPA
during the PSO On-Site Visit. The audit shall be on the process
undergoing the PSO; for PSO visits on multiple parts, the LPA review
shall include every process, not necessarily every part.
14.6 The Supplier shall maintain a list of trained LPA Team
members who shall be responsible for developing, implementing and
updating the LPA plan. The Team shall also be responsible for
uploading on-going LPA results into Powerway.com quarterly.
NOTE: On-going LPA results are NOT a requirement for PSO approval.
34
SUPPLIER READINESS EVALUATION AND EVIDENCE OF PRODUCT SPECIFICATIONS

Documentation
Supplier Readiness Evaluation (SRE)
Supplier Readiness
15.1 Prior to the Pre-PSO Meeting, the Supplier, with concurrence
Evaluation (SRE) Run
from the DCC PSO team, shall determine part quantity for the
results
Supplier Readiness Evaluation (SRE) run. Additionally, the PSO team
Measurement System
shall determine (and agree upon) the required Line Speed (see 16.1.1),
Report
as well as the number of components and characteristics to be
inspected. SRE results shall be recorded on the DCC SUPPLIER
READINESS EVALUATION form, uploaded into Powerway.com, and
reviewed by the DCC PSO Team before or during the Pre-PSO Meeting.
The DCC PSO Team shall determine SRE results to be acceptable
before scheduling the PSO On-Site Visit.
NOTE: The Supplier shall present SRE results for each production
line and/or tool.
15.2 The Supplier shall conduct SRE activities on the latest released
Production Part Number(s) with an approved Purchase Order (P.O.)
The stated part number level(s) shall have a corresponding Production
Tool P.O., with related tooling capable of meeting the required capacity
and associated line speed(s).
15.2.1 All tooling and equipment shall be at production level,
unless otherwise approved, in writing, by the DCC PSO team and
DCC ASQP Manager before the SRE is run.
15.3 During the SRE run, the Supplier shall measure and
document all characteristics on all parts per the Control Plan,
regardless of stated Control Plan frequency (e.g. measured once per
shift etc.)
15.3.1 Process performance calculations (PP and PPK) are required
for all special characteristics. Reference Element 12 Special
Product and Process Characteristics.
15.3.2 In the case of multiple production lines and tools, process
performance calculations are required for each line and/or tool.
These performance values will be used as an indication of the
beginning performance.
Measurement System Report
15.4 During the PSO On-Site Visit, PSO Team members are required
to randomly select and witness the measurement of product and/or
process characteristics (other than those on the end-item
assembly)utilizing the MEASUREMENT SYSTEM VERIFICATION
REPORT form. This audit is typically completed before the Product
Demonstration Run.
Examples:
Stock thickness for a stamped part
Moisture content, mold pressure or temperature for a
molded part
Solder-ability, dimensional checks or reflow oven profile
for an electronic printed circuit board assembly
35
SUPPLIER READINESS EVALUATION & EVIDENCE OF PRODUCT SPECIFICATIONS, CONT.

15.4.1 The PSO team shall decide the characteristics and quantity
of parts to be witnessed for measurement verification prior to the
PSO On-Site Visit (see below for minimums.) All special
characteristics shall be included. Element 12 Special Product and
Process Characteristics, cl. 12.2.
15.4.2 A minimum of 3 characteristics shall be measured.
15.4.3 A minimum of 30 parts shall be selected.
15.4.4 The PSO team shall determine if the measuring process for
each characteristic identified on the report is acceptable.
15.4.5. All identified process and/or component nonconformances, shall have root cause analyses performed and
documented (and corrective actions approved by the PSO Team)
before PSO approval can be given.
36
PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY

Documentation
16.1 During the Pre-PSO Meeting, the PSO Team (including the
Line speed calculation
Supplier) shall review all plans for required production rates. At a
Process constraints
minimum, the PSO Team shall discuss the required Line Speed, Daily
and contingency plans
Tooling Capacity, and Net Operating Time for DCC Parts. These
Final audit sampling
numbers shall be verified with the DCC Buyer.
plan
16.1.1 The PSO team shall ensure the Supplier meets the P.O.
Daily Tooling Capacity and Operating pattern.
NOTE: In situations where multiple Purchase Orders (P.O.s) exist
for the same part (as is the case for some high volume parts or
parts supplied to both US and Mexican DCC assembly plants), the
Daily Tooling Capacities from both P.O.s shall be added together
before determining the required Line Speed.
16.2 The Production Demonstration Run (PDR) shall be conducted on
all production lines of record, using production tools, production
processes, and fully trained operators.
16.2.1 The PDR consists of 300 pieces (i.e., end-item assemblies)
or two hours of production, whichever is more stringent. These
requirements apply equally to cases involving multiple production
lines and/or multiple sets of tools.
NOTE: Rework, repair, and scrap shall not be included in the PDR
line speed calculation. The line speed calculation shall only include
complete assemblies produced successfully. If the line is empty at
the start of the PDR, line fill time shall not be included. Count
completed units only, starting with the first completed
assembly off the production line.
16.3 The PSO Team shall witness and monitor the PSO Line Speed
during the PDR and record the data on the PRODUCTION
DEMONSTRATION RESULTS form. For multiple production lines
and/or tools, the line speed for each line and tool shall be recorded.
16.4 Process constraints (bottlenecks), which may impact quality
or production schedules shall be documented on the COMMENTS
SHEET, and contingency plans shall be documented and submitted to
the PSO team for approval.
16.4.1 When process constraints are attributed to high scrap,
rework and/or repair (i.e. FTC < 90%), the issue shall be
documented on the COMMENTS SHEET and the Supplier shall
identify root cause, implement permanent corrective action and
verify corrective action with a new PSO On-Site Visit prior to
receiving A approval.
37
PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY, CONT.

16.5 Test samples used in Production Validation (PV) testing shall
come from a successful PDR and PSO On-Site visit. However, the PSO
Team may elect to use test samples from an unapproved PSO On-Site
visit, provided the following requirements are met:
All process and product performance (PP and PPK) requirements
are met;
The PDR was conducted using the Daily Tooling Capacity and
the required Line Speed met;
All sub-components and materials used in the PDR had an
approved PPAP (or equivalent);
Production processes and tooling were used;
All production measuring tools had acceptable gage R&R
results.
16.6 Parts made during the PDR may be used for PPAP if and only if
all PPAP requirements, including statistical requirements, have been
successfully completed.
First Time Capability (FTC)
16.7 The Supplier shall demonstrate a First Time Capability (FTC) of
90% or greater. Deviation from this requirement shall have signed
approval from the DCC PSO Team and the ASQP Manager.
NOTE: The FTC requirement applies to the primary production line
only. Secondary, off-line, and/or support processes do not need to
meet the 90% FTC requirement, unless otherwise required by the PSO
Team.
16.6.1 For multiple production lines, tools, and/or cavities, FTC
shall be calculated separately for each one.
16.6.2 FTC is equal to the number of acceptable parts produced
divided by the number of parts rejected during the PDR (see
Appendix C FTC Calculations.
NOTE: Rework and repair are NOT counted in the number of
acceptable parts, nor are parts initially rejected by the process but
found to be acceptable after re-testing.
38
PARTS PACKAGING AND SHIPPING SPECIFICATIONS

Documentation
17.1 The parts packaging and shipping plan shall include the types of
Parts packaging and
containers (expendable or returnable) that will be used to ship product
shipping plan
to DCC or DCC-designated assembly plants.
Packaging and
Shipping Procedures
17.1.1 Specific container information shall include but is not
Packaging, shipping
limited to: returnable and/or back-up expendable, container
and labeling
dimensions, container material, pieces per container, weight of full
instructions (these
and empty container, number of containers per pallet, etc.
may be included with
Element 10 Operating
17.1.2 Shipping and labeling instructions shall conform to the
Instructions)
DCC Packaging and Shipping Instructions manual. This can be
Returnable Container
obtained through COVISINT or eCopier (84-263-8537).
Management Plan
Bar coded labeling
17.1.3 The Supplier shall be responsible for designing,
procedure
manufacturing, testing and documenting expendable packaging
Shipping label
test data (simulated or actual).
example
Simulation or
17.1.4 Testing (e.g. shaker table, rail or over the road etc.) shall
Shipping Test Results
be performed based upon the mode of transit.
17.2 When returnable containers are to be used, a Returnable
Container Management plan shall be developed which includes:
Training and access to the DaimlerChrysler Container
Management System (CMS);
A documented procedure for mandatory data entry;
Inventory control to track containers on hand and in transit;
Documented procedures for mandatory transmittal of container
and/or part number information during ASN submissions from
the Suppliers facility; and
Detail for identification and disposition of contaminated or
damaged containers.
17.3 The expendable backup plan shall ensure on-time shipment in
the event of a shortage of returnable containers. Back-up expendable
packaging shall maintain the same dimensions as the returnable
container and hold the same number of pieces.
17.3.1 Both expendable and returnable packaging shall be sized
not to exceed the DCC assembly plant requirement of two-hour-ofassembly-plant-production per container. Deviation requires
approval from DCC MHE.
17.4 Simulation tests and/or shipping tests shall be conducted prior
to S1Start and documented.
17.5 When DCC designed packaging is used (i.e., containers, racks,
etc.), the Supplier is not responsible for packaging approval(s).
17.6 PSO approval shall not be delayed due to a lack of approval(s)
for DCC provided and/or designed packaging. Any questions
concerning approval of DCC designed packaging should be referred to
the DCC Material Handling Engineering group.
39
PARTS PACKAGING AND SHIPPING SPECIFICATIONS, CONT.

Bar Code Labeling
17.7 When bar code labeling is done as the final operation of the
assembly process (i.e. at end-of-line), they shall be generated one at a
time and only following successful completion of the previous
operation (e.g. after passing an end-of-line tester, after correct
scanning of the correct material, etc.) Only one label shall be printed
at a time.
17.8 The Supplier shall have logic in place to prevent printing of
duplicate bar code labels.
17.9 The Supplier shall ensure (through logic or error and/or mistake
proofing) that part bar code labels match the part for scanning
purposes.
40
GAGE AND TEST EQUIPMENT EVALUATION

18.1 All gages used in the process shall be listed on the Control Plan.
18.2 The Supplier shall refer to the Design and/or Process FMEA to
determine the appropriate gage to be used (attribute or variable).
18.3 The Supplier shall have a procedure to validate gages and test
equipment prior to release onto the manufacturing floor. See the
Measurement System Analysis AIAG manual.
18.4 All gages and testing equipment shall have acceptable R&R
studies performed prior to the Pre-PSO Meeting.
Documentation
Gage R&R results
Gage layout results
Gage and test
equipment validation
procedure
Gage and test
equipment calibration
records
Calibration schedule
18.4.1 Total R&R as a percent of part tolerance shall be used for

new processes, while total R&R as a percent of process variation
shall be used for process improvement.
18.4.2 Acceptable gage R&R as a percentage of tolerance shall be
less than 10%. The gage R&R as a percent of study variation shall
also be less than 10%. A gage R&R between 10% and 30% shall
require approval from the DCC PSO team. A gage R&R equal to or
greater than 30% is unacceptable.
18.4.3 For attribute gages the organization shall complete a study
per the AIAG Measurement System Analysis manual or shall use a
minimum of 50 samples, three operators, and three sets of
measurements from each operator. The samples shall include parts
that are close to each side of the specification(s). All measurements
taken on parts that are out of specification shall indicate that the
parts are to be rejected.
NOTE: Attribute gauging is only allowed on special characteristics
if approved by the DCC PSO Team.
18.5 For variable gages, tolerances used for 100% verification shall be
reduced by the extent of Gage R&R.
18.6 All gages and test equipment shall be calibrated and reflect the
last calibration and expiration dates. Calibrations shall be traceable to
a known source and/or standard.
18.7 A calibration schedule shall be established for all gages and test
equipment. There shall be detailed procedures for calibration of any
equipment done internally (i.e. at the Supplier.)
18.7.1 The Supplier shall have an effective system to ensure that
the calibration of equipment is done per schedule. A reaction plan
shall be established for containment of equipment that is out of
calibration.
18.7.2 3rd party sources used for gage and test equipment
calibration shall be evaluated by the Supplier and be certified to
ISO/IEC 17025. See ISO/TS-16949 cl. 7.6.3.2.
41
PREVENTIVE MAINTENANCE PLANS

19.1 A Preventive Maintenance (PM) plan shall exist for all equipment
and tooling. The plan is a living document which shall be reviewed and
updated on a regular basis or as circumstances require. Reference
ISO/TS-16949:2002 cl. 7.5.1.4 Preventive and Predictive Maintenance.
Documentation
PM Plan (includes
schedules, frequencies,
instructions, etc.)
19.2 The PM plan shall include schedules, responsibilities and

instructions for maintaining each item of equipment. Additionally, the
plan shall outline how all frequencies were established for each piece
of tooling and/or equipment (e.g., quantitative historical data of
frequencies, material specifications, etc. and their collective impact on
equipment).
19.3 PM schedule conformity, machine performance issues and any
PM related quality issues shall be reviewed for process optimization.
The PM plan is a living document and shall include lessons learned
from similar tooling and/or equipment
19.4 The Supplier shall develop a robust PM process that ensures
preventive maintenance is performed per the established PM schedule.
(e.g., software-controlled PM that triggers an alert when PM is due).
19.5 New tooling and/or equipment shall be added to the PM schedule
prior to production release.
19.6 The PM plan shall address storage of tooling and equipment
when not in use. This plan shall provide a guideline(s) to ensure DCC
property is clean, well protected from damage and environmental
stresses, properly maintained and easy to locate.
19.7 Each Supplier shall ensure that as tooling and/or equipment
approaches the predetermined end of life cycle, appropriate actions
are taken. These actions shall ensure conformity to DCC production,
assembly, and quality requirements (e.g. increased inspections,
enhanced detection measures or methodologies).
19.8 The PM plan shall address 3rd party and/or outsourced PM
activities when applicable.
Tooling and/or equipment with 3rd Party outsourced PM
activities shall be uniquely identified on the schedule.
The 3rd Party sources shall have a PM process equal to or
better than that of the Supplier.
42
INITIAL PROCESS STUDY

20.1 It is intended that 100% of the parts from PDR be included in the
Initial Process Study. Where this is not practical, the PSO Team can
deviate and choose a lower sample size. All part samples used for the
Initial Process Study, regardless of sample size, shall come from the
PDR.
Documentation
Initial Process Study
Results
NOTE: The number of parts to be included in the Initial Process Study

shall be determined and documented by the PSO Team during the PrePSO Meeting.
20.1.1 The Capability Matrix (see Appendix B) shall be used to
determine the PP and PPK requirements for the Initial Process
Study. For attribute characteristics, the PP and PPK requirements
do not apply; however 100% of the parts shall be acceptable.
20.1.2 All identified special characteristics shall be included in the
Initial Process Study, as well as any other characteristics required
by the PSO Team. Any characteristic or measurement
automatically taken on 100% of parts (e.g. EOL tester checks,
continuity checks, etc.) shall also be included in the study.
20.1.3 If the Process Capability is less than the established
requirement, then 100% verification of shipped parts is acceptable
as an interim corrective action only with DCC PSO Team approval;
however, the Initial Process Study shall be marked Reject on the
PSO SUMMARY form. Permanent corrective actions must be
approved by the DCC PSO Team, implemented by the Supplier,
and an On-Site Visit performed (and approved) prior to Z or A
approval being granted.
20.1.3.1 Special characteristics which do not meet capability
requirements shall have a corrective action plan approved by
the DCC PSO Team and fully implemented (and meet those
capability requirements) before PSO approval can occur.
NOTE: 100% mechanical verification (i.e. mistake proofing) may be
accepted as permanent corrective action, at the discretion of the
DCC ASQP Specialist.
20.1.4 PP and PPK shall be calculated individually for each line,
tool, and/or cavity.
43
PRODUCTION VALIDATION TESTING COMPLETE

Documentation
21.1 Test samples used in Production Validation (PV) testing shall
Component level PV
come from the Production Demonstration Run.
test results (DVP&R)
PV Test procedures
21.1.1 When a single production line and/or tool will be qualified,
or multiple lines and/or tools qualified on separate tests, the PV
test components shall be selected randomly from the PDR for each
line or tool.
21.1. 2 When multiple production lines and/or tools will be
qualified in a single PV test, a portion of the PV test components
shall be randomly selected from each production line and/or tool
in proportion to that lines contribution.
21.1.3 Test samples used for PV testing shall meet the production
design release configuration.
21.1.4 When acceptable rework or repair processes are agreed
upon by the DCC PSO team, parts from the rework or repair
process shall be included in PV testing.
21.2 PV test results shall be reviewed by the PSO Team and signed
and approved by the DCC Product Engineer (see Element 3 Test
Sample Sizes and Frequencies.)
21.3 The DVP&R shall be updated with component level PV test
results.
21.4 Component level PV testing shall have been successfully
completed on all test samples. If one (or more) test samples fail, it is
unacceptable to just replace those samples. The PV test plan shall be
redone on new samples once corrective actions are done.
BSR/NVH
21.5 BSR/NVH testing results shall be included in the DVP&R,
reviewed by the PSO Team and signed and approved by the DCC
Product Engineer (see 21.2.)
21.5.1 Analyses shall include evaluations of interactions with
mating parts to reduce, eliminate and/or monitor objectionable
BSR or NVH characteristics. Potential causes shall be addressed in
the D/PFMEA, DVP&R, and the Control Plan.
21.5.2 It is the Suppliers responsibility to ensure that their parts
do not squeak or rattle in their respective environments.
21.5.3 The Supplier shall employ detailed procedures and/or test
methods to properly detect BSR and NVH without subjectivity.
The procedures are to recreate BSR and NVH, as found through
DCC testing and/or defined boundary samples (e.g. sound
chamber, shaker and actuation tests).
21.5.4 The Supplier shall have training and/or certification for
employees conducting BSR/NVH operations (e.g. hearing tests.)
44
APPENDIX A
FORMS & INSTRUCTIONS
45
Document Checklist Work Instructions
Header:
Enter Part Name, Number, Change Level, Program, Supplier,

Mfg. Location, Supplier Code and date. Header will copy to
all pages.
Document
Or Task:
Enter an X in the appropriate box. Box will change color.

(Green/Approved, Yellow/Corrections, Red/Missing,
Black/Not Applicable)
Powerway.com required documents are shaded in Blue.

NOTE 1: Corresponding box on Checklist will fill in.
NOTE 2: This form is optional. It is intended as an aid in conducting the
Pre- PSO Documentation Review meeting only.
46
PART NAME(S)
SUPPLIER
MFG. LOCATION
PART NUMBER(S)
SUPPLIER CODE
PRE-PSO MEETING DATE
CHANGE LEVEL(S)
PSO ON-SITE VISIT DATE
PROGRAM
PSO ON-SITE VISIT NUMBER
1. Part Number, Description & Change Level

1.2 D Engineering Change procedure
1.2 D CN Tracking (list of CN's, desc. & implementation)
1.3 D Software level and Hardware level
1.3 D Part number Cross reference
1.4 D List of applicable engineering standards
1.4 D Document Control procedure
1.5 D GD&T or Drawing
1.5 D Catia files,drawings,comments page,
2. Design FMEA
2.1 D DFMEA
2.2 D Best Practice Procedure
3. Test Sample Sizes and Frequencies

3.2 V DCC Engineering signed DV and PV test plans
3.3 D DCC Engineering signed DVP&R
Not Applicable
Missing/Reject
Corrections
Documentation / Task
Approved
Sec.
Enter a "X" in the

appropriate box below.
D/V/F*
All Documents
Approved
1st Review Date:

2nd Review Date:
Required Action
3.4
3.5
3.6
V Continous Conformance testing documented

V DVP&R includes Test to Flailure Plans
D Annual Validation Procedure
0
4. Process FMEA
4.1 D PFMEA
4.2 D Best Practice Procedure
4.5 D PFMEA Audit summary
5. Process Flow Diagram & Manufacturing Floor Plan

5.1 D Process Flow diagram
Mfg. Floor Plan (Location of equipment and space used identified)
5.2 D
5.2
5.4
5.6
D Cell Layout
V Process Flow or Cell layout Including # of Operators
D DFMA (Design for Manufacturing Assembly)
0
6. Control Plan and Process Monitoring

6.1 D Control Plan
6.2 D Defect Tracking sheets
6.2 D Control charts
6.2 D Process Performance charts
6.2 D Log sheets
6.3 D 1st piece approval procedure & records
7. Quality Planning
7.1 D AQP or APQP timeline/plan
7.2 D List with PPAP status of all sub components
Indented list or Easy Map of Sub-Suppliers (Name,
Manufacturing location, Part name, Part Number,
7.2 D PPAP Status) To raw material supplier.
7.2
7.2
7.3
7.4
7.6
D Listed risk of all PIA and sub-tier processes

Level 3 PPAP documentation( for PIA and sub tier processes risked
D
medium or high
D Procedure to convey Lessons Learned
Copies od eCIMS or 8-Step Corrective Actions for issues
D
encountered in previous pilot builds.
D DOE
0
8. Incoming and Outgoing Material Qualification Plan

8.1 D Incoming Inspection Plan
8.3 D Sampling Plans
8.4 D Receiving Reports
8.4 D Inspection/test reports
Copies of sub-tier Certificate of Analysis for each specific PIA
8.6 D
8.6
8.8
8.9
8.11
8.14
8.14
8.14
D
D
D
D
D
D
D
Copies of sub-tier and supplier PSW's

Copies of sub-tier Supplier ISO9001 certifcations
Outgoing Inspection Plan
Part Inspection Standard
Audit Work Instructions
Shipping Reports
Audit Records
47
9. Parts Handling Plan - WIP

9.1 D Parts Handling Plan
9.1 D Material handling Procedures
9.7 D Containment records
10. Operator Instructions

10.1 D Operator Instructions
10.1 D Set-up Sheets
10.1 D 1st Piece approval instructions
10.1 D Mistake proofing instructions
10.1 D Gage Instructions
10.2 D Operator Qualification process
10.3 D Visual Management Document control procedure
10.4 D Rework/repair instructions
11. Tooling, Equipment & Gages Identified

11.1 D Tooling List (Including Capital Equipment)
11.2 D STR (List)(Printed from DCX system)
Note: "Property of DCX" and the STR number must be on all DCX
owned tooling (Fire Proof). The STR list printed from the DCX
11.2 N system needs to be supplied to the specialist during the PSO Onsite
visit.
12. Special Product & Process Characteristics Identified

12.1 D Special Characteristics List
12.1 D PPSR (Pre-Production Sample Report) for vehicle builds
FPSC (First ProductionShipement Certification) Plan
-100% inspection of 1st 2000 GOOD parts for visual
defects and all Control plan checks (Or increased
12.5 D
frequency per team agreement)
13. Error & Mistake Proofing

13.1 D Error & Mistake Proofing Plan
List of error and mistake proofing implmented by operation number
13.1 D
13.1
13.2
D Error & Mistake Proofing Studies

D Mistake Proofing Contingency Plan
0
14. Layered Process Audit Plan

14.2 D LPA Procedures
14.2 D LPA work instructions
14.3 D LPA Structure and Frequency chart
14.4 D LPA Process Control Audit checklist
14.4 D LPA Error Proofing Verifcation Audit Checklist
15. SRE Results and Evidence of Product Specifications

SRE "Supplier Readiness Evaluation" Run results
15.1 F
16. Production Demonstration Run and FTC

16.1 F Line Speed demonstration form completed
16.4 D Process Constraints & Contingency Plans
16.4 F Final audit sampling plan
17. Parts
17.1 D
17.1 D
17.1 D
17.1 D
17.1 D
17.2 D
17.3 D
Packing & Shipping Specifications

Parts packaging and shipping plan
Packaging and Shipping procedures
Packaging,shipping and labeling instructions
Returnable Container management plan
Barcoded Labeling Procedure
Shipping label example
Simulation or shipping test results
18. Gage
18.3 D
18.2 D
18.5 D
18.5 D
18.6 D
& Test Equipment Evaluation

Gage R&R (All measurement devices) results
15.4
F Measurement Verification Report

0
Gage layout results

Gage and test equipment validation procedure
Gage and test equipment calibration records
Calibration schedule
0
19. Preventative Maintenance Plans

19.1 D PM Plan (Everything on Tooling list is in System)
20. Initial Process Study

20.1 F Initial Process Study results
21. Production Validation Testing Complete

21.1 D Component level PV test results
21.1 D PV test procedures
21.4 D Training/certification for BSR operators
21.4 D Applicable PF Standards
21.4 D Vibration Test Procedure
Key:
D
F
N
V
Document
Completed PSO form
Note
View
Powerway required document
48
DAIMLERCHRYSLER PROCESS SIGN-OFF CHECKLIST

PSO APPROVAL STATUS:
20
"N"
26
"Z"
PART NAME(S)
CHECK IF PSO EXTENDED RUN:
"A"
OPTION #
SUPPLIER
0
PART NUMBER(S)
0
0
CHANGE LEVEL(S)
PROGRAM
FPSC REVIEWED WITH SUPPLIER
MFG. LOCATION
SUPPLIER CODE
1/0/1900
DATE
PSO PROCESS ELEMENTS REQUIRED FOR "Z" APPROVAL

DOCUMENTATION
1. PART NUMBER, DESCRIPTION and CHANGE LEVEL

2. DESIGN FMEA
3. TEST SAMPLE SIZES and FREQUENCIES
4. PROCESS FMEA
5. PROCESS FLOW DIAGRAM and MFG FLOOR PLAN
6. CONTROL PLAN and PROCESS MONITORING
7. QUALITY PLANNING
8. INCOMING and OUTGOING MATERIAL QUALIFICATION PLAN
9. PARTS HANDLING PLAN
10. OPERATING INSTRUCTIONS
11. TOOLING, EQUIPMENT and GAGES IDENTIFIED
12. SPECIAL PRODUCT and PROCESS CHAR IDENTIFIED
13. ERROR and MISTAKE PROOFING
14. LAYERED PROCESS AUDIT
15. SUPPLIER READINESS EVAL and EVIDENCE OF PRODUCT SPECS
16. LINE SPEED DEMONSTRATION and FTC
17. PARTS PACKAGING and SHIPPING SPECS
18. GAGE and TEST EQUIPMENT EVALUATION
19. PREVENTIVE MAINTENANCE PLANS
20. INITIAL PROCESS STUDY
PROCESS
Accept
Reject
N/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
20
Accept
20
Reject
N/A
ADDITIONAL PSO PROCESS ELEMENTS REQUIRED FOR "A" APPROVAL

DOCUMENTATION
Accept
Reject
24
ON-SITE REVISIT REQUIRED
Process Sign-Off Team
Accept
Reject
N/A
21. PRODUCTION VALIDATION TESTING COMPLETE
CORRECTIVE ACTION REQUIRED
PROCESS
N/A
15
Yes
No
Date
Yes
No
Date
Manufacturing Facility
ENGINEERING
PRINT NAME, SIGN AND DATE
SUPPLIER QUALITY
49
PART NAME(S)
SUPPLIER
0
PART NUMBER(S)
0
0
CHANGE LEVEL(S)
PROGRAM
0
0
MFG. LOCATION
SUPPLIER CODE
1/0/1900
PROCESS SIGN-OFF
COMMENTS SHEET
ITEM
ISSUE/ACTION
RESPONSIBILITY
TARGET
DATE
CLOSED
DATE
50
51
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Item
#
Process Feature /Part

Characteristic
/Part1
Process
Meas.
Freq.
USL
UCL
Part/Proc
Avg.
LCL
LSL
Pp
Ppk
PERFORMANCE RESULTS
SHIFT:
Quantity
Attempted
SUPPLIER READINESS EVALUATION

0
0
1/0/1900
Quantity
Accepted
SUPPLIER CODE
MFG. LOCATION
SRE LINE RATE:
SUPPLIER NAME
DAIMLERCHRYSLER PSO TEAM:
QUANTITY DETERMINED BY SUPPLIER AND
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
FTC Percent (without

repairs)
% GR&R
5th Edition
ACC/ REJ
Supplier Readiness Evaluation Instructions

Note: When requesting approval for multiple manufacturing lines, a SRE form shall be
completed for each manufacturing line requesting approval.
Quantity Determined by Supplier and DaimlerChrysler PSO Team: Number of parts agreed by
DaimlerChrysler and the Supplier prior to the SRE run.
SRE Line Rate: The calculated line rate for the Supplier Readiness Evaluation run = SRE Part
Quantity Accepted Duration of SRE run.
Shift: The manufacturing shift the SRE was performed. Record shift # and hours. (e.g. 1st shift,
6am-3pm)
Process Feature/Part Characteristic: The process feature or part characteristic that is being
measured.
Process/Part: Document if data is for a process measurement or a part measurement.
Meas. Freq.: Measurement Frequency. Record the number of part/process measurements taken
per time interval.
USL: Upper Specification Limit. The upper limit of the part or process specification per the part
drawing or process standard.
UCL: Upper Control Limit: The upper limit established by the Supplier for process/part control.
NOTE: This number should be less than the USL.
Part/Proc. Avg.: Part/Process Average. The average of all measured process features/part
characteristics.
LCL: Lower Control Limit. The lower limit established by the Supplier for process/part control.
NOTE: This number should be less than the LSL.
LSL: Lower Specification Limit. The lower limit of the part or process specification per the part
drawing or process standard.
PP: The calculated PP for all measured process features/part characteristics.
PPK: The calculated PPK for all measured process features/part characteristics.
Quantity Attempted: The total number of part/process measurements taken.
Quantity Accepted: The total number of part/process measurements acceptable per the
established controls (within the LCL-UCL).
FTC percent (without repairs): Calculated First Time Capability. For further details, please see
Appendix C.
% GR&R: Calculated percentage of Gage R&R for gage used for part/process measurement.
Acc/Reject: Has the PSO team determined the suppliers data to be acceptable (acc) or
unacceptable (Reject)? [i.e. LCL <Proc Avg < UCL; Ppk Ppk matrix requirement (see Initial
Process Study element); FTC 90%; GR&R < 10% ; 10< GR&R < 30 PSO team decision].
52
DCC FORMULA FOR PRODUCTION DEMONSTRATION RUN

PSO REQUIREMENT
PART NAME(S)
PART NUMBER(S)
SUPPLIER
MANUFACTURING LOC
SUPPLIER CODE
CHANGE LEVEL(S)
PROGRAM
Calculation
Data input from production P.O.:
Input information
Shared Line? Yes or No (Y/N)

A) Combined DCC P.O. Daily Tooling Capacity
A1) DCC P.O. Daily Tooling Capacity
Part Number
Part Number
Part Number
Part Number
Part Number
Total (A1 + A5)
Pieces/day
Pieces/day
Pieces/day
Pieces/day
Pieces/day
Pieces/day
B) DCC P.O. Shift Pattern

B1) Number of shifts per day
B2) Production hours per shift
B3) Number of production days per week
shifts
hours
days
Data input from manufacturing process:

C) Downtime
C1) Lunches
C2) Breaks
C3) Changeover and/or set-up
C4) Operating time dedicated to other customers
hours/shift
hours/shift
hours/shift
hours/shift
C5) Scheduled/unscheduled downtime (as applicable)
D) Parts attempted during the PDR

E) First time through fallout during the PDR
F) Length of PDR in hours
G) Acceptable parts witnessed at the PDR
Start:
hours/shift
Finish:
attempted parts
failed parts
hours
pieces
In process calculations:
H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)]
I) Available production hours/day [B1*H]
J) DCC required parts per hour at the PDR [A/I]
K) Witnessed parts per hour at the PDR [G/F]
hours/shift
hours/day
parts/hour
parts/hour
Requirements:
L) FTC calculation [((D-E)/D)*100]
M) Difference between witnessed parts/hour and required parts/hour [K-J]
%
pieces
53
Production Demonstration Run Calculation Work Instructions

Shared Line? Yes or No (Y or N)
A)
The combined DCC Daily Tooling Capacity should be obtained from the DCC Purchase Order - "TOOL CAP"
If shared line = N:
A1)
Input the Daily Tooling Capacity and part number from the DCC Purchase Order.
A2-A5)
Leave as the default 0.
If shared line = Y, shared with DCC parts only:
A1-A5)
Input the Daily Tooling Capacity and part number from the DCC Purchase Order for the various parts being
validated.
NOTE: The assumption for this calculation is that all of the part numbers have the same operating pattern and the same
takt time.
NOTE: If the components being validated have varying operating patterns or different takt times, then separate calculation
worksheets should be completed for each part.
If shared line = Y, shared with other customers:
A1-A5)
Input the Daily Tooling Capacity from the DCC Purchase Order for the various parts being validated.
C4)
In hours/shift, input the time dedicated per shift to other customers.
NOTE: The assumption for this calculation is that all of the part numbers have the same operating pattern and the same
takt time.
NOTE: If the components being validated have varying operating patterns or different takt times, then separate calculation
worksheets should be completed for each part.
B)
The shift pattern should be obtained from the DCC Purchase Order - "SH/HR/DY"
B1) Number of shifts per day - "SH" on Purchase Order
B2) Production hours per shift - "HR" on Purchase Order
B3) Number of production days per week - "DY" on Purchase Order
NOTE: Please input appropriate comments in the blanks provided.
C)
Downtime per shift

C1) Lunches - The amount of time, in hours per shift, that the production process is not operating due to lunch.
C2) Breaks - The amount of time, in hours per shift, that the production process is not operating due to breaks.
C3) Changeover and/or set up - The amount of time, in hours per shift, that the production process is not operating due
to changeover and/or set up activities. Only changeovers that were quoted to occur during the production operating
pattern should be considered for this calculation.
Changeovers or set up not conducted every shift should be calculated on a per shift basis (e.g. Changeover time per
week divided by the number of shifts per week = changeover time per shift).
NOTE: Please indicate when during the production process the changeovers will be implemented (if they are conducted
during the quoted operating pattern, or if they are to be conducted during "off shifts").
C4) Operating time dedicated to other customers - The amount of time, in hours per shift, that the production process is
operating/manufacturing product for other customers.
Operating time dedicated to other customers calculated on a per shift basis (e.g. operating time per week divided by the
number of shifts per week = changeover time per shift).
C5) Scheduled/unscheduled downtime not considered - The amount of downtime, in hours per shift, that was not
considered. This could be any downtime such as PM, changeover, etc. that was not included in the development of the
shift pattern/pieces per day quantity.
Scheduled/unscheduled downtime should be calculated on a per shift basis (e.g. operating time per week divided by
the number of shifts per week = changeover time per shift).
D) The parts attempted during the PDR are the total number of parts the supplier produced including rejects/scrap.
E) First time through fall out during the PDR is the number of parts that were rejected from the manufacturing process during
first evaluation. This is not the final number of unacceptable parts, but only those that failed first time through the
process. (This number will be used in the FTC calculation.)
F) Length of PDR in hours is the measured time it took to conduct the production demonstration run. Please input start and
finish time in cells provided.
G) Acceptable parts witnessed at the PDR are the total number of parts, minus any rejects, which were demonstrated during
the production run. (May differ from first time through fallout.)
54
Production Demonstration Run Calculation Work Instructions, cont.

H) Available production hours/shift are the net hours per shift the supplier has available to build product not including any
scheduled downtime.
I)
Available production hours/day are the net hours per day the supplier has available to build product.
J) DCC required parts per hour at the PDR are the total number of acceptable parts the supplier must produce, in an hour's
time, necessary to satisfy DCC.
K) Witnessed parts per hour at the PDR are the number of acceptable parts witnessed by the PSO team, which the supplier
produced within an hour's time.
L) FTC (First Time Capability) is the percentage of acceptable parts witnessed at the production demonstration run out the
total number of parts attempted at the PDR.
If the DCC requirement of 90% or greater is met, the cell will turn green.
If the DCC requirement is not met (less than 90%), the cell will turn red.
NOTE: If the FTC is less than 90%, the PSO team shall take product and process technology, complexity, supplier
experience, and the effectiveness of defect containment actions into account when deciding whether the demonstrated lower
FTC values are acceptable with a documented deviation. A DCC Supplier Quality Manager's signed approval is required for
deviation from the PSO FTC requirement.
M) The difference between required parts/hour and witnessed parts/hour gives the total number of parts over or under the
DCC requirement.
If the part difference is greater than (the DCC required parts per hour + 10%), the cell will turn green indicating the
line speed is acceptable. i.e. (J + 10%) M, then cell = green (requirements met).
If the part difference is between 0 and (the DCC required parts per hour + 10%), the cell will turn yellow indicating the
line speed has met requirments, but the part difference is very close and may require additional attention.
i.e. 0 <= M < (J+10%) then cell = yellow.
If the part difference is less than 0, the cell will turn red indicating the requirement is not met. i.e. M < 0 the cell = red.
NOTE: In the event (M) is yellow, it is strongly advised to conduct an Extended Run PSO to stress the supplier's
production line and increase confidence in the supplier's ability to meet DCC requirements. PSO Extended Run
options are explained in the PSO manual. Continuous improvement actions should also be developed for bottleneck
operations or other operations which showed poor performance during the PSO run.
55
56
P025 Gap - Machine 66
P025 Gap - Machine 67
Process Feature / Part

Characteristic
Item
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Process Feature / Part

Characteristic
Item
#
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
Process /Part
Meas.
Freq.
2/Shift
Part
2/Shift
Meas.
Freq.
Part
Process /Part
USL
0.097
0.097
USL
UCL
0.00895
0.00895
UCL
Part/Proc Avg.
0.0874
0.0874
Part/Proc Avg.
LCL
0.0851
0.0851
LCL
LSL
0.077
0.077
LSL
Summary Example
Pp
2.54
2.5
Pp
Ppk
2.41
2.28
Ppk
INITIAL PROCESS STUDY
Quantity Attempted
30
30
Quantity Attempted
SUPPLIER CODE
MFG. LOCATION
SUPPLIER
Quantity
Accepted
30
30
Quantity
Accepted
0
0

repairs)
100%
100%

repairs)
1/0/19005th Edition
ACC
ACC
ACC/ REJ
% GR&R ACC/ REJ
12.70%
9.37%
% GR&R
DaimlerChrysler
Initial Process Study

Process Feature/Part Characteristic: The process feature or part characteristic that is being measured.
Process/Part: Document if data is for a process measurement or a part measurement.
Meas. Freq.: Measurement Frequency. Record the number of part/process measurements taken per time
interval.
USL: Upper Specification Limit. The upper limit of the part or process specification per the part drawing or
process standard.
UCL: Upper Control Limit: The upper limit established by the Supplier for process/part control.
NOTE: This number should be less than the USL.
Part/Proc. Avg.: Part/Process Average. The average of all measured process features/part characteristics.
LCL: Lower Control Limit: The lower limit established by the Supplier for process/part control.
NOTE: This number should be less than the LSL.
LSL: Lower Specification Limit. The lower limit of the part or process specification per the part drawing or
process standard.
PP: The calculated PP for all measured process features/part characteristics.
PPK: The calculated PPK for all measured process features/part characteristics.
Quantity Attempted: The total number of part/process measurements taken.
Quantity Accepted: The total number of part/process measurements acceptable per the established
controls (within the LCL-UCL).
FTC percent (without repairs): Calculated First Time Capability. For further details, please see Appendix C.
% GR&R: Calculated percentage of Gage R&R for gage used for part/process measurement.
Acc/Reject: Has the PSO team determined the suppliers data to be acceptable (acc) or unacceptable?
[i.e. LCL <Proc Avg < UCL; PP PPK matrix requirement (see Initial Process Study element); FTC 90%;
GR&R < 10% ; 10%< GR&R < 30% PSO team decision].
57
58
0
0
COMMENTS:
CHARACTERISTIC
SPECIFICATION
(3.6 - 7.5 mm)

(2.0 0.02 mm)
Length
Hole Size
Number of parts witnessed:
SPECIFICATION
CHARACTERISTIC
DATA
METHOD OF MEASUREMENT
Witnessed By:
CALIPER
CMM MACHINE
METHOD OF MEASUREMENT
QUANTITY
ATTEMPTED
30
30
QUANTITY
ATTEMPTED
SUMMARY EXAMPLE
QUANTITY
ACCEPTED
30
28
QUANTITY
ACCEPTED
MEASUREMENT SYSTEM REPORT

0
FTC PERCENTAGE
(without repair)
100%
93%
FTC PERCENTAGE
(without repair)
1/0/1900
SUPPLIER CODE
SUPPLIER NAME
MFG. LOCATION
As part of the PSO, the actual measurement process must be witnessed by the PSO Team.
- A minimum of 3 characteristics are to be checked. For any given part, assembly, or process,
the number of characteristics selected depends upon the complexity.
- A minimum of 30 randomly selected samples shall be checked during the PSO on-site visit.
- Variable data is preferred but attribute data is acceptable.
- Refer to the Ppk Capability Matrix (Appendix B of the PSO 5th Edition Manual) for Ppk requirements.
- For attribute data, a 30 piece sample with one or more non-conformances is unacceptable.
- All deviations shall be listed in the COMMENTS section of this document.
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
PP / PPK
1.7/1.6
2.3/2.2
PP / PPK
PROCESS ACC/REJ
REJ
ACC
PROCESS ACC/REJ
DaimlerChryler
Measurement System Report Instructions

The MEASUREMENT SYSTEM VERIFICATION REPORT is used to document the results of the measurement
audit performed during the PSO On-Site Visit. Use additional copies of the form or attach additional pages
as needed to accommodate more characteristics.
Number of parts witnessed: The number of parts the PSO has personally witnessed the supplier measure
characteristics.
Witnessed by: The names of all the DCC PSO team members who witnessed the measurement audit.
Characteristic: Measurement characteristics identified by the team to be measured.
Specification: The documented specification of the characteristics as identified on the part drawing.
Method of Measurement: The gage, fixture, or equipment used to measure the identified characteristics.
Quantity Attempted: The total number of parts chosen to be measured by the team (this may exceed the
number of parts witnessed by the PSO team members).
Quantity Accepted: The number of parts which whose characteristic was within the specification.
FTC percentage (without repair): Calculated FTC. For further details, please see Appendix C.
PP/PPK: The calculated PP/PPK for the quantity of parts attempted.
Process Acc/Reject: Has the PSO team determined the suppliers measurement process to be acceptable
(acc) or unacceptable (Reject)?
Comments: Any waivers/deviations should be recorded here for documentation purposes.
59
How to find the Daily Tooling Capacity and Operating Pattern

For DaimlerChrysler Specialists:
Log onto the Supplier Quality Portal at
https://gsp.extra.daimlerchrysler.com/SQP/servlet/SQPServlet
Move mouse to Summaries and click on Part Summary from the drop-down menu
Enter the part number and click on the Fetch box
Additional MY information can be found by moving the mouse over the indicated area
60
APPENDIX B
Tables and Examples
61
LOT ACCEPTANCE SAMPLING TABLE

Sample Size Per Characteristic Classification
Acceptance
Number = 0
Lot Size or Shipment

Size*
<S> / <E>
0-15
<D>
100% Inspection
16-25
26-50
51-75
50
76-125
75
65
126-225
90
75
226-425
100
85
426-1300
110
90
1301 and up
115
90
NOTE 1: THIS TABLE APPLIES TO ATTRIBUTE SAMPLING ONLY.

NOTE 2: TWO OR MORE OF THE METHODS DESCRIBED IN ELEMENT 7.4.3.1 OF TS-16949
SHALL BE USED, OTHERWISE, THIS TABLE APPLIES.
Characteristics Definition
SAFETY <S>/EMISSION <E>: A characteristic that will affect compliance with DaimlerChrysler
Corporation and/or Governmental Vehicle Safety/Emission requirements.
KEY <D>: A characteristic that is key to part function and has particular quality, reliability, and
durability significance (Refer to Engineering Process Standard PS-7300).
Sample size shall be based upon the normal production lot size. If the lot size is temporarily
reduced due to material shortages or production problems, the sample size will not change. If the
temporarily reduced lot size is smaller than the required, production sample size, inspect 100%. A
lot is not to exceed one shift or one-day's production whichever is smaller.
PRODUCT QUALIFICATION
SAMPLE RESULTS
ACTIONS ON PROCESS
ACTIONS ON LOT
No Nonconforming units
Continue to operate
Accept
One or more
Nonconforming units
Find Root Cause(s) and

Correct Process
Sort 100% since last

conforming lot
62
CAPABILITY MATRIX
There are two risks inherent in every decision, either (1) we have accepted bad parts (consumers risk), or
(2) we have rejected good parts (producers risk). Test plans seek to balance these risks by specifying
sample size and/or acceptance criteria so that neither the consumer nor the producer carries the higher
proportion of risk.
Sometimes, for business or other reasons, it may be important to hold one risk constant and allow the other
risk to float based on sample size. Such is the case for Pp and Ppk. DaimlerChrysler wants to minimize its
risk of accepting a population below 1.33Ppk.
The following table presents the sample size and acceptance criteria that keeps the risk of accepting a bad
population ( 1.33) at 6.4% (93.6% that population > 1.33 Ppk will be accepted). Depending upon sample
size, the risk of rejecting a good population ( 1.67) could be very high. The table allows for trade-offs
between sample size and producers risk to be identified.
Sample Size
Acceptance Ppk
Criteria
Risk of Accepting a
Population <= 1.33Ppk
Risk of Rejecting a
Population >= 1.67Ppk
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
150
200
250
300
2.94
2.10
1.89
1.78
1.71
1.67
1.64
1.61
1.59
1.58
1.56
1.55
1.54
1.53
1.52
1.52
1.51
1.50
1.50
1.49
1.46
1.44
1.43
1.42
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
86.3%
77.3%
68.7%
60.7%
53.3%
46.5%
40.4%
34.9%
30.1%
25.8%
22.0%
18.7%
15.9%
13.4%
11.3%
9.5%
8.0%
6.7%
5.6%
4.7%
1.9%
1.0%
0.6%
0.3%
63
1st Layer of
Management
Supervisors Supervisor 1
2nd Layer of
Management
Area
Managers
Supervisor 2
Own Department
Supervisor 3
Own Department
Area Manager 1 Own Area
Plant Staff
and Plant
Manager
1 per 1 per
shift shift
2 per
week
2 per 2 per 2 per

week week week
2 per 2 per
week week
Engrng Mgr
Rotate Depts.
1 per week
Quality Mgr
Rotate Depts.
1 per week
Tooling Mgr
Rotate Depts.
1 per week
H.R. Mgr
Rotate Depts.
1 per week
Training Coord.
Rotate Depts.
1 per week
Plant Manager
Rotate Depts.
1 per week
Department F
1 per 1 per
shift shift
Area Manager 2 Own Area

3rd Layer of
Management
Department E
1 per
shift
Department D
1 per
Own Department shift
Audit
Assignment
Department C
Assigned
Management
Personnel
(example)
Department B
Assigned
Management
Category
(example)
Department A
EXAMPLE: LPA FREQUENCY AND STRUCTURE
64
FMEA GUIDELINES
Special Attention Shall Be Given To:

I. RPNs that have a Severity
Detection level.
8 regardless of RPN value, Occurrence level, or
II. RPN's that have Severity 5 and an Occurrence 2 regardless of Detection and
RPN value. (This equates to customer dissatisfaction and C/1000 >1).
III. Detection = 10. (The potential defect is allowed to leave the plant and reach the
field).
65
66
APPENDIX C
FTC Calculations
67
First Time Capability

CALCULATING FIRST TIME CAPABILITY (FTC) AND PROCESS YIELD WITHOUT
REPAIRS
PURPOSE
First Time Capability (FTC) is part of a process capability study that identifies how well it produces quality
parts. For multiple assembly lines or tools, FTC studies shall be conducted on each one. FTC can be an
important measure, because generally the lower the value, the greater the amount of rework required. As
defects and rework increase, there is a greater possibility that the Supplier will ship non-conforming parts.
DaimlerChryslers requirement for FTC is 90% or greater. Following the PDR, the PSO Team shall review the
FTC values for each operation and the overall process. If the FTC is less than 90%, the PSO team shall take
product and process technology, complexity, Supplier experience, and the effectiveness of defect
containment actions into account when deciding whether the demonstrated lower FTC values are acceptable
with a documented deviation. A Supplier Quality Managers signed approval is required for deviation from
the PSO FTC requirement.
FTC can be used to prioritize product and process improvement. If a Supplier encounters a situation where,
despite their best efforts, they cannot find a solution to an inherently low FTC, DaimlerChrysler can assist
in the improvement effort by supplementing the Supplier's team with experienced engineering and
manufacturing specialists from a wide variety of disciplines.
DESCRIPTION
FTC is measured as the number of items processed correctly divided by the total number of items
processed. Correctly processed means no repairs or rework are allowed. Therefore, in a multi-operation
process, a higher FTC is expected for an operation or zone than for an entire process.
DATA COLLECTION PROCEDURE

This three-step procedure is suggested for calculating a production line FTC.
1.
2.
3.
Create a block diagram for the process showing each operation. The flow diagram or floor layout
provided by the plant can also be used.
Collect the following data from the PDR.
a. Quantity of assemblies attempted.
b. Quantity of rejected assemblies from each operation.
c. Quantity of acceptable assemblies from the end of the line. Do not include repaired or reworked parts.
Calculate the operation and process FTC using the examples as a guide.
68
First Time Capability

CALCULATIONS & EXAMPLES
Example 1, Series Process Flow without Repair:
During a typical PSO Production Demonstration Run, the goal is to show that the production line
is capable of producing parts that meet DCC quality and volume requirements. FTC and Yield are
equal for a process without repairs so only FTC calculations will be shown in Section I. For
established production lines and carryover component production demonstrations that may
include rework, refer to Examples 3 & 4.
Using the three-step, data collection procedure outlined above, the following processed and
rejected quantity data were collected during the PDR. The data are shown on the process block
diagram.
Operation 1
Operation 2
Operation 3
270 Pcs
243 Pcs
Operation 4
226 Pcs
217 Pcs
300 Pcs
30 Pcs
Rejected
17 Pcs
Rejected
27 Pcs
Rejected
9 Pcs
Rejected
Figure 1
Example 1 - Series Process Flow Diagram With Demonstration Data
Begin by calculating the FTC for each operation. Operation 1 is shown here with its respective
PSO PDR data
Divide the quantity completed at Operation 1, 270 units, by the

quantity attempted at the operation, 300 units. The result is the
operation FTC.
Operation 1
270 Pcs
300 Pcs
FTCOp 1
30 Pcs
Rejected
Qty Completed
Qty Attempted
270
300
0.90 or 90%
Figure 1A
In a similar manner, calculate the FTC for each operation in the process using Equation 1. The
general operation model is shown in Figure 1B. Table 1 shows a summary of the quantities and
FTCs for the process in Example 1.
Quantity
Attempted
Operation
Number
Quantity
Completed
FTCOPERATION
Qty Completed
Qty Attempted
Equation 1
Quantity
Rejected
(1)
Figure 1B
69
Operation
Quantity
Attempted
Quantity
Completed
FTC
300
270
0.90
270
243
0.90
243
226
0.93
226
217
0.96
TABLE 1
Quantities and FTCs for Example 1
Enter the calculated operation FTCs in their respective operation blocks of the process diagram.
Calculate the process FTC by dividing the quantity completed for the process, 217 units, by the
quantity attempted 300 units.
Total Qty Completed 217
FTCPROCESS
0.723 or 72.3%
Total Qty Attempted 300
Enter the FTCPROCESS value on the process diagram. The completed Example 1 process diagram is
shown in Figure 2. The diagram can be included with the final PSO documents as a record of the
process starting capability.
Operation 1
FTC
90%
Operation 2
270 Pcs
FTC
90%
Operation 3
243 Pcs
FTC
93%
Operation 4
226 Pcs
FTC
96%
217 Pcs
FTC = 72.3%
300 Pcs
30 Pcs
Rejected
17 Pcs
Rejected
27 Pcs
Rejected
9 Pcs
Rejected
Figure 2
Example 1 - Series Process With Operation and Process FTC's Shown
Example 2, Series/Parallel Process Flow without Repair:

Using the three-step data collection procedure outlined on page D.2, the following processed and
rejected quantity data were collected during the PDR. The data are shown on the process diagram
in Figure 3.
Operation 3
96 Pcs
94 Pcs
2 Pcs
Rejected
Operation 1
Operation 2
288 Pcs
Operation 4
Operation 6
242 Pcs
265 Pcs
218 Pcs
91 Pcs
81 Pcs
300 Pcs
12 Pcs
Rejected
10 Pcs
Rejected
23 Pcs
Rejected
24 Pcs
Rejected
Operation 5
78 Pcs
67 Pcs
11 Pcs
Rejected
Figure 3
Example 2 - Series / Parallel Process Flow Diagram With Demonstration Data
70
Calculate the FTC for each operation in the process using Equation 1 and the operation model
shown in Figure 1B on page 2. Table 2 shows a summary of the quantities and FTCs for the
operations in
Example 2.
Operation
Quantity
Attempted
Quantity
Completed
FTC
300
288
0.96
288
265
0.92
96
94
0.98
91
81
0.89
78
67
0.86
242
218
0.91
TABLE 2
Quantities and FTCs for Example 2
Enter the calculated operation FTCs in their respective blocks on the process diagram. Calculate
the process FTC by dividing the total quantity completed, 218 Units, by the quantity attempted,
300 units. The result is the FTC for the process.
FTCPROCESS
Qty Completed
Qty Attempted
218
300
0.726 or 73%
Add the process FTC to the process diagram. The completed diagram for Example 2 is shown in
Figure 4. The diagram can be included with the PDR report to document the initial process
performance.
96 Pcs
Operation 3
94 Pcs
FTC
98%
2 Pcs
Rejected
Operation 2
Operation 1
FTC
96%
288 Pcs
FTC
92%
Operation 6
Operation 4
265 Pcs
91 Pcs
FTC
89%
242 Pcs
81 Pcs
FTC
90%
218 Pcs
FTC = 72.6%
300 Pcs
12 Pcs
Rejected
10 Pcs
Rejected
23 Pcs
Rejected
78 Pcs
Operation 5
FTC
86%
24 Pcs
Rejected
67 Pcs
11 Pcs
Rejected
Figure 4
Example 2 Series / Parallel Process With Operation and Process FTCs Shown
71
CALCULATING FIRST TIME CAPABILITY (FTC) AND PROCESS YIELD WITH REPAIRS
DATA COLLECTION PROCEDURE
The recommended procedure for data collection for a process with repair is similar to the
procedure shown in Section I. Step #2 differs because of the need to record rework quantities
returned to the process stream. Step #3 differs because there are two values to calculate, FTC and
yield.
1.
Create a block diagram for the process showing each operation. The flow diagram or floor
layout provided by the plant can also be used.
2.
Collect the following data from the demonstration run.

a. Quantity of assemblies attempted.
b. Quantity of rejected assemblies from each operation.
c. Quantity of rejected assemblies that were repaired for each operation.
d. Quantity of acceptable assemblies from the end of the line.
3.
Calculate the operation and process FTC and yield using the examples as a guide.

Example 3, Series Process Flow with Repair:
In some instances, the PDR will be performed on an existing production line with rework
operations. These situations require the ability to determine FTC and Yield separately because
FTC and Yield are not equal when rework is included. The primary goal for production
demonstration is to demonstrate that the production line is ready and capable of producing at the
required quality and quantity. Rework is not part of production demonstration. There are times,
however, when we must consider the impact of rework on process output. For those times, this
section should be used as a guide to calculate FTC and Yield.
Using the three-step, data collection procedure outlined above, the following processed and
rejected quantity data were collected during a PDR. The data are shown in Figure 5.
Operation 1
270 Pcs
Operation 2
268 Pcs
Operation 3
265 Pcs
Operation 4
264 Pcs
300 Pcs
30 Pcs
Rejected
19 Pcs
27 Pcs
25 Pcs
16 Pcs
10 Pcs
9 Pcs
Rework
Rework
Rework
2 Pcs
Scrap
3 Pcs
Scrap
1 Pc
Scrap
Figure 5
Example 3 Series Process Diagram With Demonstration Data Added
72
Calculate the FTC for each operation. Operation 1 is shown here with its respective production
demonstration data.
Operation 1
Divide the quantity completed, 270 pieces, by the quantity attempted,

300 pieces.
Note: Equation 1 from Section I can be used for this operation because
rework was not performed.
270 Pcs
300 Pcs
30 Pcs
Rejected
FTC OP 1
Figure 5A
Qty Completed
Qty Attempted
270
300
0.90 or 90%
The yield for Operation 1 is the same as the FTC because rework was not performed. Therefore,
YieldOP 1
Operation 2
270 Pcs
268 Pcs
270
300
0.90 or 90%
For Operation 2, subtract the quantity rejected, 27 units, from the

quantity attempted, 270 units. Divide this total by the quantity
attempted. For Operation 2, Equation 2 will provide the correct result
because rework was performed.
27 Pcs
25 Pcs
FTCOP 2
Qty Attempted Qty Re jected

Qty Attempted
FTCOP 2
270 27
270
Rework
243
270
0.90 or 90%
2 Pcs
Scrap
Calculate the yield for Operation 2 by dividing the quantity completed,

268 units, by the quantity attempted, 270 units. Refer to Equation 3.
Figure 5B
YieldOP 2 =
Qty Completed 268

=
= 0.99 or 99%
Qty Attemp ted 270
In a similar manner, calculate the FTC and Yield for the remaining operations using Equations 2
and 3. The general operation model is shown in Figure 5C. Table 3 shows the quantities, FTCs
and Yields for the operations in Example 3.
Operation
Number
Quantity
Attempted
Quantity
Reworked
Quantity
Completed
FTCOperation =
Qty Attemp ted - Qty Rejected

Qty Attemp ted
Equation 2
Quantity
Rejected
Rework
YieldOperation =
Qty Completed
Qty Attemp ted
Equation 3
Figure 5C
73
Operation
Quantity
Attempted
Quantity
Rejected
FTC
Quantity
Reworked
Quantity
Completed
Yield
300
30
0.90
N/A
270
0.90
270
27
0.90
25
268
0.99
268
19
0.93
16
265
0.99
265
10
0.96
264
0.996
TABLE 3
Quantities, FTCs, and Yields for Example 3
A simplified sketch of the series operations that will be used for the process FTC calculation is
shown in Figure 6. Enter the operation FTCs in their respective blocks on the sketch. Calculate
the process FTC by multiplying the individual operation FTCs together.
Operation 1
Operation 2
Operation 3
Operation 4
FTC=90%
FTC=90%
FTC=93%
FTC=96%
264 Pcs
300 Pcs
Figure 6
Simplified Process Sketch for Example 3
FTCPROCESS
(FTC Op 1)(FTC Op 2)(FTC Op 3 )(FTC Op 4 )
FTCPROCESS
90% 90% 93% 96%
0.723 or 72.3
YieldPROCESS =
Qty Completed
Qty Attemp ted
YieldPROCESS =
264
= 0.880 or 88%
300
Calculate the process yield using Equation 3.
Add the operation and process FTCs and Yields to the process diagram. The completed process
diagram for example 3 is shown in Figure 7. The diagram can be included as part of production
demonstration report to document the starting process capability.
Operation 1
270 Pcs
FTC=90%
Yield=90%
Operation 2
268 Pcs
FTC=90%
Yield=99%
Operation 3
265 Pcs
Operation 4
FTC=96%
Yield=99.6%
FTC=93%
Yield=99%
264 Pcs
FTC = 72.3%
YIELD = 88.0%
300 Pcs
30 Pcs
Rejected
27 Pcs
19 Pcs
16 Pcs
25 Pcs
10 Pcs
9 Pcs
Rework
Rework
Rework
2 Pcs
Scrap
3 Pcs
Scrap
1 Pc
Scrap
Figure 7
Example 3 - Series Process With Operation, Process FTC's, and Yield Shown
74
Example 4, Series/Parallel Process Flow with Repair:

Using the three-step, data collection procedure outlined on page 5, the following processed and
rejected quantity data were collected during a demonstration run. The data are shown in Figure 8.
102 Pcs
Operation 3
107 Pcs
2 Pcs
to Rwk*
Operation 1
288 Pcs
Operation 2
283 Pcs
97 Pcs
Operation 4
276 Pcs
Operation 6
275 Pcs
92 Pcs
300 Pcs
12 Pcs
11 Pcs
to Rwk*
23 Pcs
18 Pcs
84 Pcs
27 Pcs
28 Pcs
Operation 5
Rework
Rework
77 Pcs
18 Pcs
12 Pcs
to Rwk*
5 Pcs
Scrap
Rework*
Op 3,4,& 5
1 Pc
Scrap
25 Pcs
Rework*
7 Pcs
Scrap
Figure 8
Example 4 - Series / Parallel Process With Demonstration Data Added
Calculate the FTC and yield for each operation using Equations 2 and 3. Notice that Operation 1
does not include any rework so FTC and Yield will be the same. This is not true for any other
operation in the Example 4 process. The general operation model is shown in Figure 5C. Table 4
shows a summary of the quantities, FTCs, and Yields for the operations in Example 4.
Operation
Quantity
Attempted
Quantity
Rejected
FTC
Quantity
Reworked
Quantity
Completed
Yield
300
12
0.96
N/A
288
0.96
288
23
0.92
18
283
0.98
102
0.98
107
1.05
97
11
0.89
92
0.95
84
12
0.86
77
0.92
276
28
0.90
27
275
0.99
TABLE 4
Example 4 Quantities, FTCs, and Yields
Enter the FTCs and yields that were calculated for Operations 1 through 6 in their respective
operation blocks of the process diagram. The entries for Example 4 are shown in Figure 9.
75
102 Pcs
Operation 3
FTC=98%
Yield=105%
107 Pcs
2 Pcs
to Rwk*
Operation 1
288 Pcs
FTC=96%
Yield=96%
Operation 2
283 Pcs
97 Pcs
Operation 4
FTC=92%
Yield=98%
FTC=89%
Yield=95%
23 Pcs
11 Pcs
to Rwk*
276 Pcs
Operation 6
FTC=90%
Yield=99%
92 Pcs
275 Pcs
300 Pcs
12 Pcs
18 Pcs
84 Pcs
28 Pcs
Operation 5
FTC=86%
Yield=92%
Rework
27 Pcs
Rework
77 Pcs
18 Pcs
12 Pcs
to Rwk*
5 Pcs
Scrap
Rework*
Op 3,4,& 5
1 Pc
Scrap
25 Pcs
Rework*
7 Pcs
Scrap
Figure 9
Example 4 - Process With Operation FTC's and Yields Shown
102 Pcs
Operation 3
107 Pcs
2 Pcs
to Rwk*
97 Pcs
Operation 4
92 Pcs
Qty Attempted = 102 + 97 + 84 = 283

Qty Rejected = 2 + 11 + 12 = 25
11 Pcs
to Rwk*
84 Pcs
The process shown in Figure 9 has three operations in parallel,

Operations 3, 4, and 5. To simplify the FTC calculation, reduce the
three parallel operations, shown in Figure 9A, to an equivalent, single
operation as shown in Figure 9B. Total the quantity attempted and
quantity rejected, then enter the values on an equivalent operation
sketch such as 9B.
Operation 5
Equivalent
Operation 3,
4, & 5
77 Pcs
18 Pcs
283 Pcs
12 Pcs
to Rwk*
Rework*
Op 3,4,& 5
25 Pcs
Rework*
7 Pcs
Scrap
25 Pcs
Rejected
Figure 9 A
Figure 9B
Calculate the equivalent operation FTCEq 3,4, 5. The equivalent single operation FTC calculation
using the total attempted quantity, 283 units, and the total rejected quantity, 25 units, is shown
below.
FTCEQ
Qty Attempted Qty Re jected

Qty Attempted
FTCEQ =
( 102 + 97 + 84 ) - ( 2 + 11 + 12 ) 283 - 25 258

=
=
= 0.912 or 91%
( 102 + 97 + 84 )
283
283
76
A simplified sketch of the process that will be used for the FTC calculation is shown in Figure 9C.
Multiply the individual operation FTCs together to obtain the FTC for the process, FTCPROCESS.
Operation 1
Operation 2
Equivalent
Operation 3,
4, and 5
Operation 6
FTC=96%
FTC=92%
FTC=91%
FTC=90%
Figure 9C
Simplified Process Sketch for Example 4
FTCPROCESS = ( FTC1 FTC2 FTCEQ FTC6 )

FTCPROCESS = ( 96% 92% 91% 90%) = 0.723 or 72%
Calculate the process yield using Equation 3 as shown below.
YieldPROCESS
Qty Completed
Qty Attempted
YieldPROCESS
275
300
0.917 or 92%
Add FTCPROCESS and YieldPROCESS to the process diagram. The completed diagram for Example 4 is
shown in Figure 10. The diagram can be included with the final PSO documents as a record of the
starting performance.
102 Pcs
Operation 3
FTC=98%
Yield=105%
107 Pcs
2 Pcs
to Rwk*
Operation 1
288 Pcs
FTC=96%
Yield=96%
Operation 2
283 Pcs
97 Pcs
Operation 4
FTC=92%
Yield=98%
FTC=89%
Yield=95%
23 Pcs
11 Pcs
to Rwk*
276 Pcs
Operation 6
FTC=90%
Yield=99%
92 Pcs
275 Pcs
FTC = 72%
YIELD = 92%
300 Pcs
12 Pcs
18 Pcs
84 Pcs
FTC=86%
Yield=92%
Rework
27 Pcs
28 Pcs
Operation 5
77 Pcs
Rework
18 Pcs
12 Pcs
to Rwk*
5 Pcs
Scrap
Rework*
Op 3,4,& 5
1 Pc
Scrap
25 Pcs
Rework*
7 Pcs
Scrap
Figure 10
Example 4 - Series / Parallel Process With Operation and Process FTC's and Yields Shown
77
78
APPENDIX D
PSO Extended Run
79
PSO Extended Run

This activity is intended for new vehicle launches or major vehicle upgrades to reduce the risk of the vehicle
launch. It does not impact the PSO approval process described in this manual but is a supplemental
activity to further assure a Suppliers readiness to support the full volume production with capable
processes (see Figure 1).
PSO Process as described in the PSO manual
PSO Extended Run
Increased
confidence of
Supplier
readiness on
selected parts
Figure 1
It is important for the PSO Team to decide the type of PSO Extended Run that will be accomplished and the
timing, so it can be integrated into the PSO planning process. In some cases there will be additional pieces
built or multiple shifts exercised during the Production Demonstration Run and in other cases there will be
additional visits made at later dates to ensure readiness as launch approaches.
Due to the variety of manufacturing processes utilized at Suppliers, the final details of a PSO
Extended Run for a particular part are decided by the PSO Team. The following reference options (15) have historically been used but other, more applicable, options may be developed as indicated in
option number 6.
Option Number
1
2
Option Description
Option Benefit
Expanded production of 1000

or more parts during the PSO
PDR.
Perform 2 separate PSO PDRs
with the last run occurring
prior to S2 MRD.
Perform 3 separate PSO PDRs:
Prior to S1 MRD
Prior to S2 MRD
Prior to V1 MRD
Perform PSO PDRs on multiple
shifts at the Supplier.
In addition to the Pre-S1 PSO,
perform a post-launch PSO
occurring 2-5 weeks after V1
Launch.
Any combination of the above 5
options or an appropriate
variation for the specific
commodity.
Higher confidence level that the Supplier can

sustain line rate over a longer period of time.
Confirms that the Supplier can start the process
up on multiple occasions and meet capability and
line rate.
Verifies Suppliers process consistency and
validates readiness for V1 Launch.
Ensures operational readiness on all shifts.
Validates the line rate after several weeks of
operation.
Allows flexibility to accommodate unique

circumstances.
Table 1
80
APPENDIX E
Forever Requirements
81
DCX Forever Requirements Process

1. Supplier proposed changes and/or improvements that may require part submission.
2. If changes and/or improvements affect fit, form, function and/or require DCX print modifications or
have associated costs; then the Supplier must follow the DCX Engineering CN process (i.e., refer to the
appropriate DCX procedures).
3. All other proposed changes (part, process, Tier 2 source, etc.) shall follow the Forever Requirements
process outlined here. Table 3.1 in the PPAP 4th Edition AIAG manual gives some examples of situations
requiring Forever Requirements submissions.
4. Supplier fills out page one (1) of the DCX Forever Requirements/ODD Box Activity Form. Note: Please
be advised, that this form must be submitted a minimum of three (3) months in advance of the planned
change(s) implementation date or within sufficient time for implementation (as determined by DCX).
5. Supplier submits entire DCX Forever Requirements/ODD Box Activity Form to the appropriate
Engineer. Note: if the change(s) affects multiple platforms, then the Supplier must submit a copy of the
DCX Forever Requirements/ODD Box Activity Form to each affected platform Engineer.
6. The Engineer will fill out page two (2) Section 2.A. If approved by the Engineer, the Supplier will then submit the
entire DCX Forever Requirements/ODD Box Activity Form to the appropriate Supplier Quality Specialist. If the
change(s) was rejected by the Engineer, then the Supplier must correct the rejected item(s) and resubmit the DCX
Forever Requirements/ODD Box Activity Form to the Engineer. Failure to resubmit the form to the Engineer for
approval will end the Forever Requirements process for the proposed change(s).
7.
After approval by the Engineer, the Supplier Quality Specialist will fill out page two (2) Section 2.B. If approved by
the Supplier Quality Specialist, the Supplier will submit the form to the appropriate Buyer. If the change(s) was
rejected by the Supplier Quality Specialist, then the Supplier must correct the rejected item(s) and resubmit the
DCX Forever Requirements/ODD Box activity Form to the Supplier Quality Specialist. Failure to resubmit the
form to the Supplier Quality Specialist will end the Forever Requirements process for the proposed change(s).
8.
After approval by the Supplier Quality Specialist, the Buyer will fill out page two (2) Section 2.C. If approved by
the Buyer, the submitted change(s) are fully approved by DCX. If the change(s) was rejected by the Buyer, then the
Supplier must correct the rejected item(s) and resubmit the DCX Forever Requirements/ODD Box Activity Form to
the Buyer. Failure to resubmit the form to the Buyer will end the Forever Requirements process for the submitted
change(s).
9. The approval (or rejection) process should be concluded by all affected DCX personnel within 10
business days.
10. A fully signed electronic DCX Forever Requirements/ODD Box Activity indicates that DCX approves the
plan ONLY.
11. After the DCX Forever Requirements/ODD Box Activity Form is approved, the Supplier(s) will complete
all remaining tasks including the successful completion of all PER, PSO, PPAP, and other required
activities including and appropriate hard copy and/or electronic notification as necessary.
12. After approval by all affected DCX personnel, the Supplier will make copies of the DCX Forever
Requirements/ODD Box Activity Form and distribute it to all appropriate DCX personnel as indicated
by the Supplier Quality Specialist. In addition, the Supplier will retain the original copy of the fully
approved DCX Forever Requirements/ODD Box Activity Form.
13. Supplier will submit fully approved form(s) and/or information into Powerway.com as required.
Please be advised, the hard copy format is being replaced by an electronic Forever Requirement
(eFR CN System). Tentative date time frame is early 2007.
82
Forever Requirements Process Flow

1) Supplier Proposes Change
"Forever Requirements" process begins
Does the change affect fit, form,

function, or cost?
Yes
Follow DCX CN/ODD Box Procedure;

"Forever Requirements" process ends
No
Supplier completes page 1 of "DCX Forever

Requirement Activity" form and submits one
to DCC Product Engineer for each affected
vehicle/platform. Submission must be a
minimum of 90 days before the
proposed effective date of the
change(s).
Supplier provides
additional information
as required.
Need more
information
DCC Product Engineer(s) completes

section 2.A. of the form
Approved by DCC Product

Engineer?
No
Yes
Supplier submits form to DCC ASQP

Specialist
Supplier provides
as required.
Need more
information
DCC ASQP Specialist completes section

2.B. of the form (including Risk Level)
Approved by DCC ASQP Specialist?

No
DCC Approval not provided;

Yes
Supplier submits form to DCC Buyer

Supplier provides
as required.
Need more
information
DCC Buyer completes section 2.C. of form
Approved by DCC Buyer?

No
Yes
83
Forever Requirements Process Flow, cont.

A
Supplier given approval to proceed with

change(s). Timing of change(s), including
PSO, is determined/approved by the Team
(DCC Buyer, ASQP Specialist, and Product
Engineer, and the Supplier.)
Risk Level (section 2.B. of form)
High
Follow PSO process for DCC

Lead PSO
Low
Follow PSO process for

Supplier Lead PSO
Supplier successfully completes all PSO

requirements, as well as all requirements
from DCC Product Engineering, ASQP
Specialist, and Buyer on page 2 of the form
Supplier completes all Powerway.com

requirements and submits PPAP (as
applicable)
Supplier implements change 100%
84
85
86
APPENDIX F
DCC Internal PSO Requirements
87
Internal Powertrain PSO

3 Steps to Approval
PV
Testing
Production
Demonstration Run
(PDR) & Analysis
Documentation
88
Internal Powertrain PSO

Documentation
The following documentation will be supplied for final PSO approval by the following DCX groups; Product
Engineering, Advanced Manufacturing Engineering, and the internal Powertrain Plant.
Product Engineering
Release Part Prints w/ Change Verification/ Level Identified
CATIA comments sheet (list of Engineering standards on sheet)
A copy of applicable performance, process and material standards (PF Standards)
Engineerings procedure for documentation revision changes due to part number changes
Engineerings procedure for obtaining and distributing CATIA revisions
DFMEA
Internal best practice document for DFMEA development
DVP&R (DaimlerChrysler Engineering signed DV test plan, DaimlerChrysler Engineering signed
completed DVP&R for DV testing, DaimlerChrysler Engineering signed PV test plan)
Documented waivers for any testing
Engineering MQAS procedure for Problem Solving
Supplier definition of and internal requirements for special product and process characteristics
DaimlerChrysler Engineering signed DVP&R for PV test results (MANDATORY ENGLISH
DOCUMENT)
PV test procedures (MANDATORY ENGLISH DOCUMENT)
DaimlerChrysler Engineering approved BSR results (if applicable) (MANDATORY ENGLISH
DOCUMENT)
Advanced Manufacturing Engineering
AMEs procedure for documentation revision changes due to part number changes
PFMEA (MANDATORY ENGLISH DOCUMENT)
Internal best practice document for PFMEA development
Process Flow Diagram (MANDATORY ENGLISH DOCUMENT)
Manufacturing floor plan
Work Station Layout
Dimensional Control Plan
Best Practice document for developing Control plans (input from FMEA & Control plans for similar
products)
Authorization to Ship (ATS Package)-Equipment Qualification at the Plant
AME MQAS procedure for Problem Solving
89
Tooling List
Tool Layouts
Assembly Graphics
Tool & Op Sheets
Spare Parts List
Error and mistake proofing plan. This includes a list of error and mistake proofing by operation
number
Line Speed Simulation
AME MQAS procedure for gauge identification
PM plan, schedule, procedure and work instructions
Plant Deliverables
Plants procedure for documentation revision changes due to part number changes
Plants procedure for obtaining and distributing CATIA revisions
Control Plan (MANDATORY ENGLISH DOCUMENT)
Best Practice document for developing Control plans (input from FMEA & Control plans for similar
products)
PPAP status list
Plant MQAS procedure for Problem Solving
Incoming inspection plan and procedures
Incoming sampling plans
Receiving reports
Material standards
Inspection/test reports
Parts Handling Plan
Material Handling procedures
Packaging Instructions
Maintenance plan for WIP (work in process) containers
Copy of Routing cards or travelers
Operator, 1st piece approval, mistake proofing, set-up, changeover, rework/repair, inspection and
packaging instructions
Record of operator training
Operator qualification process
Documentation control procedure
Visual management (displays & diagrams)
First Production Shipment Certification (FPSC) Plan (MANDATORY ENGLISH DOCUMENT)
90
Control Charts (As Applicable)

Process Performance Charts (As Applicable)
Total Production Maintenance charts
Error and mistake proofing studies
Mistake Proofing Contingency Plan (in the event mistake proofing becomes inoperable)
Control Charts (As Applicable)
Process Performance Charts (As Applicable)
Total Production Maintenance charts
Log Sheets
Defect Tracking Sheets
Corrective Action Forms
1st Piece Approval Procedure & Records
Measurement System Verification Report (MANDATORY ENGLISH DOCUMENT)
Line Speed section on Production Demonstration Results form (MANDATORY ENGLISH
DOCUMENT)
Documented deviation to the 300 part or 2 hour requirement (if applicable)
Process Constraints (bottlenecks) documented on PSO COMMENTS SHEET
Final Audit Plan
Final Audit Procedure
Final Audit Work Instructions
Part Inspection Standard (if applicable) - (MANDATORY ENGLISH DOCUMENT)
Final Audit Sampling plan
Shipping Record Example
Audit Record Example
Containment Record Example
Parts Packaging and Shipping Plan
Packaging and Shipping Procedures
Packaging, shipping and labeling instructions
Returnable Container Management Plan
Barcode Labeling Procedure
Shipping Label example
Plant MQAS procedure for gauge identification
Gage Plan
Gage R&R results (MANDATORY ENGLISH DOCUMENT)
Gage and Test Equipment Calibration Records and validation plan
91
Calibration Schedule & reaction plan

Initial Process Study results (on Production Demonstration Results form) (MANDATORY
ENGLISH DOCUMENT)
Deviations to Initial Process Study requirements documented on the PSO COMMENTS SHEET (if
applicable) (MANDATORY ENGLISH DOCUMENT)
Deviation from FTC requirement w/Commodity Supplier Quality Manager signature (if applicable)
(MANDATORY ENGLISH DOCUMENT)
Simulation or shipping test results (Corp Mat Handling)
Warranty process flow diagram (MANDATORY ENGLISH DOCUMENT)
Warranty procedures
Annual Validation Schedule
Production Demonstration Run & Analysis

Internal Powertrain Programs must adhere to the requirements outlined in element 16 of the PSO Manual
PV Testing
Internal Powertrain Programs must adhere to the requirements outlined in element 21 of the PSO Manual.
Internal Powertrain PSO Sign-off Package Requirements

To assure that all Internal Powertrain PSO requirements have been met, the Internal Powertrain Process Signoff Package should include the following documents
Internal Powertrain Process Sign-off form along with the deviations list. The sign-off form should
include all necessary signatures.
The Internal Powertrain PSO work sheet.
Production Demonstration Run (PDR) Results Form. (This is a standard PSO document titled Line
Speed Demonstration Results Form)
All required forms and reference material can be found on the Internal Powertrain PSO website.
http://advmfg.appl.chrysler.com/mfg/stmpdash/pso/index.shtml
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FREQUENTLY ASKED QUESTIONS

Please check https://gsp.extra.daimlerchrysler.com/qlty/pso/index.html for the most
current version of the FAQ.
93
1.
How far down do we go with the certification of the extended enterprise? 3rd tier? 4th tier?
Certification down to the production material Suppliers and if applicable any secondary
processes/services (e.g. plating, heat treating, etc) would be sufficient.
2.
What should our reaction plan be if Suppliers refuse to conduct PSO's on their sub-Suppliers?
PSO is part of DaimlerChrysler's Supplier evaluation and Production Part Approval Process.
According to TS-16949 and the DCC Customer-Specific Requirements for TS-16949,
Suppliers are responsible for evaluation and Production Part Approval of their sub-tiers. All
DCC Suppliers were required to be TS-16949 certified. Note that this does not require that
Suppliers perform a PSO specifically, it does require an evaluation and/or PSO-like activity.
Failure to conduct evaluations and Production Part Approval of sub-tiers is a failure to meet
TS-16949 requirements and may result in the loss of DCC business. Notify the Buyer and
P&S Management of any occurrence of this situation.
3.
Suppliers don't follow the Lot Acceptance Sampling Table. They always inspect about 5
parts/lot, lot size is 1,000 pcs. Should we force them to inspect as many as the table says?
For attribute sampling, two or more of the inspection criteria in TS-16949 shall be used,
otherwise the guidelines in the Lot Acceptance Sampling Table shall be followed. For variable
sampling, the Supplier shall be consistent with the Statistical Process Control manual
requirements.
4.
Collaborative AQP risked parts require a PSO if selected by the PSO Team. If the PSO Team
considers a product to be Self Directed, is PSO required?
Yes. All Self Directed products shall have a Supplier internally led PSO that documents and
establishes their production readiness. The Supplier's PSO documentation shall be uploaded
into Powerway.com.
All Directed AQP risked products will have both a DaimlerChrysler led AQP and PSO. All
Collaborative risked products will have a DaimlerChrysler led PSO and a Supplier led APQP.
5.
Since AAR is a requirement for PPAP, shouldnt AAR be required for PSO approval if the
process appreciably affects color?
AAR is not a requirement of PSO. Refer to the AIAG PPAP manual for an explanation of the
relationship between PSO and PPAP.
6.
If a Supplier changes a process, where does the Supplier go to start the PSO process, the
Responsible Design Engineer or the Supplier Quality Specialist? We've been told both.
Before a Supplier makes any changes to their assembly process they shall initiate a Forever
Requirements form and obtain approval from the DCC Release Engineer, ASQP Specialist,
and Buyer. The ASQP Specialist will determine the risk level of the change (if approved) and
corresponding PSO activity level.
7.
Most Suppliers use CMM printout for inspection documentation. Do we need to transfer this
data to the appropriate form?
No, a copy can be attached or a statement provided on the COMMENTS SHEET that the PSO
Team verified the measurement.
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8.
In a multi-cavity tool, should parts come from all cavities to calculate PP and PPK?
Parts should come from all cavities, however each cavity (process stream) should be
calculated individually as stated in the Statistical Process Control (SPC) manual published by
AIAG.
9.
Our forms do not have a control number or issue date. This is an ISO/TS-16949 requirement.
What should be done?
The forms are part of the manual, and they are identified in DaimlerChryslers Master Record
List.
10.
Why don't we take rework into account when calculating FTC?

Greater quantities of rejects increase the potential for greater quantities of non-conforming
parts shipped. DaimlerChrysler PSO Teams will review FTC at each Supplier to confirm that
defects have been minimized. If rework were included in the FTC calculation, it wouldn't be a
measure of First Time Capability. While we recognize that rework of in-process rejects is
common, we want to measure the true First Time Capability of the process in order to
quantify the quality potential.
Appendix C, provides a standard method and examples for calculating FTC for a new process
with no rework.
11.
Can the PSO Team accept a Production Demonstration Run which is less than 300 pieces/2
hours?
Yes. The PSO Team shall authorize any deviation from requirements (minimum of two hours
or 300 pieces, whichever is more stringent) and enter an explanation on the PSO
COMMENTS SHEET.
12.
Clarify IAA requirements.

Information regarding current interim approval requirements is located in DCC internal
procedure PSSP0108. Suppliers do not have access to this procedure and should contact
their DCC ASQP Specialist, Release Engineer or Buyer for more information regarding IAAs.
13.
You don't have to have PSO approval prior to V1 if you have an IAA. Explain the system of
tool payment after PSO elements 1-20 without an approved PSW.
IAA is not an alternative to PSO. An IAA indicates failure to meet program requirements. It
enables shipments on an interim basis to support vehicle development timing until corrective
action (PSO approval) can be completed.
After a Supplier successfully completes the first 20 elements for both documentation and
process, the ASQP Specialist enters a Z disposition into Powerway.com which, following the
submission of a dimensional warrant, allows tool payment at the discretion of the Purchasing
Agent.
14.
Can parts used for PV testing be selected from a non-successful Production

Demonstration Run?
In general, parts for PV testing shall be selected from a successful Production Demonstration
Run, however, there are exceptions. The PSO Team will review any deficiencies. A non-
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successful PDR can only be used for PV testing if the deficiencies are due to documentation
discrepancies or appearance (non-functional) issues not involving finish durability.
15.
Is the 2000 minimum quantity for FPSC a negotiable amount?

Yes, however, any deviation from the 2000 minimum shall be explained using the PSO
COMMENTS SHEET.
16.
If the PSO is not approved does this imply that there is no FPSC?
No, FPSC is still required, but it will probably extend the time period and quantity of the
FPSC.
17.
Who gets the FPSC form in the plant? Is there an organization to handle this?
The Supplier shall review the completed form with the PSO team and upload it into
Powerway.com. The Supplier shall also retain the original form for up to one year following
the launch.
18.
Regarding FPSC, what if we take a truck frame with 400 dimensions, for example. How many
frames do we need to measure? All 2000?
The PSO Team, working with the Supplier, will determine what shall be an adequate plan to satisfy the
FPSC requirements.
19.
It's critical to know where parts are going - if there are 3 truck plants, it could mean 6000
parts for FPSC.
FPSC requires that the first 2000 parts shipped to each customer facility be certified. If there
are 3 truck plants, then 6000 parts will require FPSC.
20.
Expand the FPSC explanation. Add examples for attendees to follow. Include a slide that
explains a statistical analysis of the first 2,000 pieces is required which is different than the
300 piece PSO capability study.
The 300 piece Production Demonstration Run that is part of the PSO, satisfies the
component requirements for PV testing, other testing, S1 vehicles, and S2 vehicles. These
components are not intended to satisfy the FPSC requirements. However, under certain
circumstances, the PSO Team may allow the remainder of these PSO parts, if any, to be
included with production parts shipped to the Assembly Plant. Refer to the DaimlerChrysler
FPSC procedure PSSP0106.
21.
If an offshore DaimlerChrysler employee performs a PSO in his/her local country, this manual
requires them to use English for the master documentation. This should be a team decision.
DaimlerChrysler is a global company. As stated, English is the official language of DaimlerChrysler and
therefore an English translation has to be available. It does not preclude other language versions.
22.
Who pays for additional manpower needed to support FPSC?

FPSC is a PSO requirement and any additional manpower or tooling needed to fulfill this
requirement is the sole responsibility of the Supplier.
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23.
At what level must packaging be signed off?

Supplier designed packaging shall be signed off by DaimlerChrysler Corporate and the
receiving Assembly Plant Material Handling Engineering prior to Z approval of the PSO
using the Unit Load Data (ULD) sheet (available in the DCC Packaging and Shipping
Instructions manual.) Actual packaging shipping test shall be signed off by DaimlerChrysler
Assembly Plant Material Handling Engineering prior to PSO A approval. Packaging shipping
simulation testing shall be signed off by Corporate Material Handling Engineering prior to
PSO A approval. For DCC designed packaging, PSO approval must not be delayed due
to a lack of approval(s). Any questions concerning approval of DCC designed packaging
should be referred to the DCC Material Handling Group.
24.
Is it acceptable for a Supplier to add or remove operators from a production line during the
line speed demonstration?
The number of operators required for the production line shall be identified on the Process
Flow Chart, Manufacturing Layout, and/or Workstation Layout. The Supplier may not
deviate from this number during the PDR; line-balancing and other ergonomic or efficiency
studies are expected to be completed prior to the PSO On-Site visit.
25.
If a reference characteristic is showing out-of-specification on the Initial Process Study, should

I approve the PSO?
This depends on what is meant by a reference characteristic. Strictly speaking, a reference
dimension does not have a tolerance and, therefore, cannot be out-of-specification. Basic
dimensions, on the other hand, use general print tolerances; if these are out-of-specification,
then the PSO must be rejected. All dimensions on the design model must meet and be
capable to DCC specifications, even those not regularly monitored.
26.
The Supplier has several required documents that they consider proprietary, and will not allow
us to review them. How do we handle this?
As stated in Element 7 (cl. 7.7): Note: For source packages that reflect proprietary document
exclusions, those documents sited for exclusion are not required to be uploaded into
Powerway.com. However, these documents shall be available for review at the request of the
DCC ASQP Specialist. A cover page with the documents title block, revision level and date is
required to be uploaded in place of the actual document. Review of the documents may take
place at the Suppliers location or at a DCC location, at the discretion of the team. In those
rare cases when a Supplier refuses to allow DCC personnel to review required documents at
all, the PSO should be rejected and the matter brought up to DCC management (ASQP,
Engineering, and/or Purchasing, as appropriate.)
97
REFERENCE MANUALS
DaimlerChrysler Manuals:
Packaging and Shipping Instructions
Product Assurance Testing
Test Data Analysis manual
P&S 7-Step Corrective Action Process manual
Available From:
Lanier Professional Services

Detroit Production Center
2119 Austin Ave.
Rochester Hills, MI 48309
Phone: 248.564.4748
Fax: 248.564.4679
Corporate Engineering Publications:

CEP-002 CATIA Standards Reference Manual
CEP-010 Supplier Product Design Information Security Requirements
Available From: https://essd.extra.daimlerchrysler.com/ESSD/Login.jsp
AME Standards:
AME Standards-Gage Standards
Available From: https://gsp.extra.daimlerchrysler.com/mfg/amedd/gages/index.htm
Other Manuals:
Production Part Approval Process (PPAP)
Measurement Systems Analysis (MSA) Manual
Statistical Process Control (SPC) Manual
Potential Failure Mode and Effects Analysis (FMEA)
Advanced Product Quality Planning and Control Plan (APQP) Manual
Quality Systems Requirements for Automotive Suppliers (ISO/TS 16949)
Quality Systems Requirements of VDA (VDA 6.3)
Available From:
NOTE:
Automotive Industry Action Group (AIAG)

Phone No: (248) 358-3003
DaimlerChrysler personnel can obtain copies of the manual through DaimlerChrysler's eCopier
on DashboardAnywhere.
98
GLOSSARY
99
ADVANCED QUALITY PLANNING (AQP): a structured method of defining and establishing

the required steps necessary to assure that a product satisfies the customer. AQP
embodies the concepts of defect prevention and continuous improvement as contrasted
with defect detection.
AUTOMOTIVE INDUSTRY ACTION GROUP (AIAG): a group founded in 1982 by
representatives from DaimlerChrysler, Ford, and General Motors. The purpose of the
AIAG is to provide an open forum where members cooperate in developing and promoting
solutions that enhance the prosperity of the automotive industry. AIAG's focus is to
continuously improve business processes and practices involving trading partners
throughout the supply chain. The AIAG website is at http://www.aiag.org/.
BOUNDARY SAMPLES: part samples created as a visual inspection aid for operators.
Samples are typically created at the specification limits (e.g. go and no-go) or at the
worst-possible acceptable condition (e.g. no worse than.) Boundary samples must be
clearly marked and/or identified to prevent shipment to the customer and properly
controlled to prevent degradation and ensure relevance.
BUZZ SQUEAK RATTLE (BSR): objectionable vehicle noise attributes. All BSR issues
are tracked by Vehicle Development and subsequently assigned to the most responsible
party for resolution, be it Engineering, Manufacturing, or the Supplier. Although
somewhat subjective, BSR issues shall be eliminated in order to achieve customer
satisfaction.
CAPABILITY STUDY: is a statistical analysis of the output from a machine or a process to
determine its ability to produce product that meets specifications. This analysis is
especially important when a new product is introduced so product quality and variation
reduction can be assessed.
CATIA: is a computer aided three dimensional interactive applications design and
manufacturing system. This software was developed and is maintained by Dassault
Systemes of France and is marketed in the United States by IBM. It is known as a
CAD/CAM system.
CHRYSLER DEVELOPMENT SYSTEM (CDS): CDS provides a framework for a total
systems approach to Product Creation. This framework will shorten the overall time for
the development and launch of a vehicle, while providing a forum for sharing. Consistency
among product teams is achieved by using a standard process. The CDS process keeps
the design window open for a longer period to ensure products meet or exceed external
requirements. At the same time, it ensures that the design and feasibility for both product
and process is complete prior to execution. This is key to the CDS process. By completing
design and feasibility prior to execution using virtual design tools, costly changes are
eliminated in the execution and launch phase. The CDS website is at
http://roadmap.tcc.chrysler.com/cds/what_is_cds.htm.
CONTINUING CONFORMANCE TESTING (CC): tests and evaluations performed after
production launch to monitor the effects of processing and to assure continued
conformance to engineering requirements.
CONTROL PLANS: written descriptions of the systems for controlling parts and processes.
They are written by Suppliers to address the important characteristics and engineering
100
requirements of the product. Each part shall have a Control Plan, but in many cases,
family Control Plans can cover a number of parts produced using a common process.
Customer approval of Control Plans may be required prior to production part submission.
COVISINT: A web based system that grants qualified Supplier users access to selected
portions of the DaimlerChrysler Network.
CP: capability index that compares the process capability to the maximum allowable
variation as indicated by the tolerance. This index provides a measure of how well the
process will satisfy the variability requirements. CP is not impacted by process location.
This index can be calculated only for two-sided (bilateral) tolerances. (Statistical Process
Control Manual, pg. 132)
CP=
USL - LSL
6 C
Where,
USL LSL
6 R
d2
USL = Upper Specification Limit

LSL = Lower Specification Limit
= Estimate of the standard deviation of a stable process using the average
C
range of subgrouped samples taken from the process
= Average range of a series of subgroups of constant size
R
d2
= A divisor of R used to estimate the process standard deviation (see the

Statistical Process Control Manual (AIAG) Appendix E.
CPK: capability index that takes the process location as well as the capability into
account. (Statistical Process Control Manual, pg. 132)
C PK
CP
CP and CPK are equal only when the process is centered.

CPK is calculated as the minimum of CPU or CPL, where:
CPU =
CPL =
Where,
USL - X
3 C
USL
LSL
3
3 R
3 R
and
d2
LSL
d2

X
C
= The average of subgroup averages (measured process average)

= Estimate of the standard deviation of a stable process using the average
range of subgrouped samples taken from the process
R
d2
= Average range of a series of subgroups of constant size

= A divisor of R used to estimate the process standard deviation (see the
Statistical Process Control Manual (AIAG) Appendix E.
101
CUSTOMER SATISFACTION AUDIT (CSA): a comprehensive review of a vehicles asshipped quality as it leaves an assembly plant. The CSA provides a reliable real-time
indicator of vehicle quality.
DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA): formalized method for
quantifying the risk associated with identified potential design failure modes. It is used to
identify corrective actions required to prevent failures from reaching the customer. The
DFMEA is a living document that is updated as the design changes and progresses
through design verification and production.
DESIGN OF EXPERIMENTS (DOE): a statistical approach to efficiently plan and structure
a series of controlled tests. In its broadest sense, it encompasses planning, setting up,
and running the tests, and analyzing the data. The goal is to identify the sources of
product variation that should be optimized or avoided for consistent product performance
with a minimum number of tests.
DESIGN VERIFICATION PLAN AND REPORT (DVP&R): formalized test planning and
reporting tool. It lists all testing necessary to assure that functional and reliability criteria
and target requirements are defined in specific measurable terms. It provides a
convenient reporting format for Engineering Development (ED), Design Verification (DV),
Production Validation (PV) and Continuing Conformance (CC) testing.
DESIGN VERIFICATION (DV) TESTING: testing phase that demonstrates the final
released component or assembly meets design intent. The tests, sample sizes, and
performance requirements are detailed in Engineering Performance Standards.
DRAWING CHANGE LEVEL (DCL): the latest design level of the released drawing. It is a
two digit alpha field that can be accessed on ODCICS2 through screen ENAA or ENJA.
ELECTRONIC CORPORATE ISSUE MANAGEMENT SYSTEM (e-CIMS): DCCs electronic
system for documenting serious issues that arise during vehicle prototype, launch, or
volume production phases.
ENGINEERING STANDARDS: are written requirements that describe materials,
processes, performance, reliability, quality and/or design requirements for a material,
process, or part or a family of materials, parts, or systems.
ENGINEERING STANDARDS SUPPLIER DISTRIBUTION (ESSD): the DCC computer
system that gives Suppliers access to DCC Engineering Standards. It is available on-line
at https://essd.extra.daimlerchrysler.com/ESSD/Login.jsp.
ERROR PROOFING: Error proofing is a method used to identify potential process errors
and either designs them out of the product or process, or eliminate the possibility that the
error could produce a defect. Examples of error proofing include:
A rod clip designed to work in left- and right-handed parts (as opposed to separate
clips for each;
A hole or slot designed so that mating parts can only fit in the proper orientation;
An operation that will not function until all components are present in the proper
orientation.
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EXTENDED ENTERPRISE : is a DaimlerChrysler coordinated process that unifies and

extends the business relationships of Suppliers and Supplier tiers in order to maximize
the effectiveness of vehicle development, minimize total system costs, and improve quality
and customer acceptance.
FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC): the purpose of FPSC is to
ensure that initial production shipments meet all DCC product specifications. FPSC is
intended to identify part problems and contain the parts at the Suppliers manufacturing
facility during the launch phase. FPSC requires the Supplier to provide statistical
evidence of conformance to special product and/or process characteristics prior to the
shipment of components to the DCC (or DCC-designated) assembly plant. Certification is
for a minimum of 2000 parts (per assembly plant) or for a specified period of time as
identified by the PSO team. 100% of the FPSC parts are to be inspected for conformance
to special product and/or process characteristics.
FIRST TIME CAPABILITY (FTC): FTC is equal to the number of acceptable parts
produced divided by the number of parts rejected during the PDR. Rework and repair are
NOT counted in the number of acceptable parts, nor are parts initially rejected by the
process but found to be acceptable after re-testing. See Appendix C for examples.
GAGE DIMENSIONING & TOLERANCING (GD&T): a system of symbols used to define
part and part feature shape, size, position, tolerances, etc.
GAGE REPEATABILITY & REPRODUCIBILITY (R&R): a method used to rate the
appropriateness of a measurement system as a percentage of the product tolerance or
process variation. Repeatability is a measure of the ability of the gage to repeat a given
measurement, and is evaluated by repeatedly measuring the same parts (equipment
variation). Reproducibility is a measure of the ability of people to reproduce a series of
measurements using the same gage, and is evaluated by two or more operators
independently repeating the inspection of a set of parts (appraiser variation).
HOME LINE: Suppliers assembly line located in the manufacturing facility where volume
production of the part(s) takes place using production tooling and processes.
INTERIM APPROVAL AUTHORIZATION (IAA): documentation and approval to temporarily
use a part that does not meet PPAP approval requirements for Pilot builds, launch, or
production.
ISO/TS 16949: is a Technical Specification that describes, in conjunction with ISO
9001:1994, the Quality System Requirements for Automotive Suppliers. ISO/TS 16949
has been prepared by the International Automotive Task Force (IATF) for all participating
worldwide OEMs.
KEY <D> CHARACTERISTICS: designated by the or <D> symbols on Engineering
Source Documents. Key Product Characteristics are toleranced and measurable
characteristics (i.e. dimensions, torque etc.) of a part, component or assembly that may
cause failure to meet customer satisfaction specifications due to manufacturing and/or
assembly, and therefore, require special attention to ensure acceptable results. Reference
PS-7300 Key Product Characteristics the Use of Diamonds for additional information.
103
LINE SPEED: the contracted maximum tool capacity rate determined by dividing the
Daily DaimlerChrysler Tooling Capacity (Pieces per Hour) by the Suppliers Net Operating
Time for DaimlerChrysler Parts (Hours/Day). The Line Speed shall be verified during the
Production Demonstration Run.
LOT: specific amount of material or group of components; not to exceed eight hours or
one days production, whichever is smaller.
MANUFACTURING FLOOR PLAN: a pictorial layout of the entire manufacturing facility
drawn to scale. It is to include all machinery, office space, lab space, shipping-receiving
areas, quarantine areas, hold areas, etc. The layout shall also indicate any proposed areas
for expansion and development.
MISTAKE PROOFING: Mistake proofing is an approach used to develop methods to
clearly identify errors that may occur and prevent them from becoming nonconformances. Examples of mistake proofing include:
Sensors, optics, and/or vision systems that detect missing or incorrectly-assembled
components;
End-of-line (EOL) testers that check functional requirements;
Pick lights or barcoding to assist in proper part selection;
Continuity testing for electrical components.
NET OPERATING TIME FOR DAIMLERCHRYSLER PARTS: equal to the number of hours
(normal work pattern), less scheduled down-time (e.g. breaks, start up, preventive
maintenance, shared production, tool changeovers, shut-down, etc.) and time scheduled
to run other customers parts and/or other DCC parts.
NON-CONFORMANCE TRACKING (NCT) SYSTEM: DCCs electronic system for
documenting and tracking part issues at the manufacturing plants. It also provides a
method for replacement of those parts and for Supplier dispute of the issue. Serious
quality issues are also documented in the e-CIMS system.
NVH: Noise Vibration Harshness are measurable perceptions of vehicle attributes.
These items are usually discovered and measured by DaimlerChryslers NVH laboratory
facilities. NVH attributes are typically tuned to a certain frequency and amplitude in order
to achieve an overall vehicle signature frequency. This signature is optimized by vehicle
development for the best customer responses.
OPERATOR INSTRUCTIONS: lists of steps in performing an operation that may contain
inspection requirements, required tools and gages, SPC applications, sample size and
frequency, and acceptance/rejection criteria. They shall communicate all requirements
involved in that particular operation. These shall be readily available to the operator.
PACKAGING: material that is used to store and ship parts. It provides protection and
containment of parts. It affects ease of handling by manual or mechanical means.
Packaging may consist of returnable or non-returnable items including dunnage.
PART CHANGE LEVEL (PCL): the latest design level of the part (not necessarily the
drawing). It is a two digit alpha field found on ODCICS2 through screens ECCE or ENCZ.
104
PART SUBMISSION WARRANT (PSW): an industry-standard document required for all

newly-tooled or revised products in which the Supplier confirms that inspections and
tests on production parts show conformance to customer requirements.
PERISHABLE TOOLS: tools which are consumed in the process of producing a product,
and are usually a cost item, e.g., drill bits, cutters, sockets, driver tips, inserts, hobs,
broaches, welding tips, etc.
PP: performance index that compares the process performance to the maximum allowable
variation as indicated by the tolerance. This index provides a measure of how well the
process will satisfy the variability requirements. PP is not impacted by process location.
(Statistical Process Control Manual, pg. 133)
PP =
USL - LSL
6 P
Where,
USL LSL
6s

= Estimate of the standard deviation of a stable process using the sample
P
standard deviation of a set of individuals about the average of the set.
= Sample standard deviation for subgroups or processes; see the Statistical
s
Process Control manual, Chapter II, Section C or Chapter IV, Section A.
PPK: performance index that takes the process location as well as the performance into
account. (Statistical Process Control Manual, pg. 133)
PPK
PP
PP and PPK are equal only when the process is centered.

PPK is calculated as the minimum of PPU or PPL, where:
PPU =
PPL =
Where,
USL - X
3 P
USL X
3s
LSL
3
and
LSL
3s

X
P
= The average of subgroup averages (measured process average)

= Estimate of the standard deviation of a stable process using the sample
standard deviation of a set of individuals about the average of the set.
= Sample standard deviation for subgroups or processes; see the Statistical
Process Control manual, Chapter II, Section C or Chapter IV, Section A.
PRE-PSO DOCUMENTATION REVIEW: a meeting conducted by the PSO Team, chaired

and coordinated by the ASQP Specialist, with the Supplier. The meeting is conducted at a
DCC selected location prior to the PSO On-Site visit. The purpose is to review all of the
105
Suppliers required documentation in a sequential way and determine the Suppliers

readiness for the Production Demonstration Run (300 pcs.) and PSO On-Site Visit.
Generally, a Pre-PSO meeting is held for Directed and Collaborative AQP activity level
programs; it is not a requirement for programs with a Self-Directed AQP activity level.
PRE-PRODUCTION SAMPLE REPORT (PPSR): a dimensional and performance verification
document, submitted with all part samples used prior to S1 Start.
PREVENTIVE MAINTENANCE (PM): a planned system of actions performed to prevent
breakdown of a machine or equipment as a result of normal use.
PROCESS CAPABILITY: the 6 C range of inherent variation in a stable process. Reference
the Statistical Process Control AIAG manual for more information.
PROCESS PERFORMANCE: the 6 P range of total process variation. Reference the
Statistical Process Control AIAG manual for more information.
PROCESS FAILURE MODE & EFFECTS ANALYSIS (PFMEA): a structured method of
documenting historical or potential process failure modes, their effects, and the controls
taken to ensure their detection and/or prevention. The PFMEA rating system allows
quantification of the risk presented by each failure mode with the Risk Prevention
Number (RPN). The RPN is used to prioritize recommended actions. The PFMEA is
developed by a cross-functional team and is uniquely developed for each process/product.
PROCESS FLOW DIAGRAM: chart that illustrates the flow of materials through the
process. The diagram generally starts at receiving, and includes work in process,
production, shipping (including any special processing which may result from a
nonconformance requiring disposition), and rework or repair operations.
PROCESS SIGN-OFF (PSO) ON-SITE VISIT: a systematic and sequential review of the
Suppliers manufacturing process conducted by a PSO Team at the Suppliers production
facilities. The ASQP Specialist is responsible for leading the PSO On-Site Visit for Directed
and Collaborative AQP activity level programs; the Supplier leads their own for SelfDirected AQP activity level programs.
PRODUCTION DEMONSTRATION RUN (PDR): a production run conducted during the
PSO On-Site Visit consisting of at least 300 parts or 2 hours of production (whichever is
more stringent). The PDR is on the production line of record, with trained operators, PPAP
(or equivalent) approved components and materials, and run at a rate equal to the daily
maximum tooling capacity. The DCC PSO Team will be on the manufacturing floor during
the PDR for all Directed and Collaborative AQP activity level programs. PV test parts are
taken from the PDR to demonstrate that the production process has not degraded the
design performance that was verified during DV testing.
PRODUCTION PART APPROVAL PROCESS (PPAP): process for ensuring that production
parts are manufactured that meet customer requirements. Parts PPAP shall be taken from
a significant production run. DaimlerChrysler requires that this run is a minimum of two
(2) hours or 300 pieces, whichever is more stringent, unless otherwise stated in writing by
the customer. Parts from each position of a multiple cavity die, mold, tool or pattern are
to be measured and representative parts tested. Reference the PPAP 4th Edition AIAG
106
manual and the DaimlerChrysler (Chrysler Group) Customer-Specific Requirements for

the PPAP 4th Edition for more information.
PRODUCT SPECIFICATIONS: all engineering drawing requirements including standards
referenced on those drawings and within the pre-source package. Some of these
requirements are determined by team consensus during Advanced Quality Planning
meetings and Design Reviews and can take the form of Safety Standards, Material
Standards, SRPCs, Temporary Standards, Process Standards, Laboratory Standards,
Reliability Standards, or Performance Standards.
PRODUCTION VALIDATION (PV) TESTING: tests performed to validate design
conformance of initial production parts manufactured with production tools and
processes.
REPAIR: action taken on non-conforming product so that the product will fulfill its
intended usage, although the product may or may not conform to specification.
REWORK: action taken on non-conforming product so that it will meet specification.
ROOT CAUSE: the assignable source of variation that affects all the individual values of
the process output or phenomenon being studied. Root cause is the reason for the
primary nonconformance, which has induced other failures and for which effective
permanent corrective action can be implemented.
S0 START CDS Quality Gate D1. S0 is the first pilot build program based on product
components and systems that meet design specification, produced off tools and
equipment allowing build to production process intent. It includes vehicle and property
builds that verify product and process design and train key plant personnel. Components
may be built using hard or soft tools, as determined to be appropriate based on part or
process knowledge required. Design verification (DV) testing shall be successfully
completed before parts are submitted for S0.
S1 START: CDS Quality Gate C. S1 is a home plant build to validate tooling, equipment
and verify facilities. Vehicles are built for the certification test plan. Components for S1
are required to be PSO and PPAP approved.
S2 START: CDS Quality Gate [no letter designation]. S2 is the home plant facility
validation build. Vehicles are built for fast feedback and rental fleet feedback programs,
and for dealers.
S
SAFETY <S> CHARACTERISTICS: Designated by the

or <S> symbols on Engineering
Source Documents. They are product characteristics or manufacturing process
parameters which can affect safety or compliance with government regulations. See PFSAFETY Product Safety Use of Safety Shields <S> for more information.
SAMPLING PLAN: plan that defines the minimum number of parts that shall be inspected
from a given population (see DaimlerChryslers Lot Acceptance Sampling Table Plan in
this manual).
SEQUENTIAL SENSING: type of sensor that detects if a series of operations are
performed in the correct order. Example: A station requires that an assembly receives a
107
screw, washer, and nut (in that order.) A sequential sensor would detect and flag
(through lights, station lock-out, etc.) if the nut was put on before the washer.
SPECIAL CHARACTERISTICS: product characteristics or manufacturing process
parameters which can affect safety or compliance with regulations, fit, function,
performance or subsequent processing of product. They include all governmental, Key
(diamond) <D>, emissions <E>, safety (shield) <S>, torque requirements, and
characteristics identified as SPC points on the design model. See PS-7300 - Key Product
Characteristics the Use of Diamonds for more information regarding Key characteristics
and PF-SAFETY for additional information regarding Safety characteristics.
STATISTICAL CONTROL: the condition describing a process from which special causes of
variation have been eliminated. Only common causes remain; e.g., observed variation
could be attributed to chance causes. On a control chart, statistical control is evident by
the absence of points beyond the control limits and by the absence of non-random
patterns or trends within the control limits.
STATISTICAL PROBLEM SOLVING (SPS): the organized use of special problem solving
tools (e.g. Fishbone Diagrams, Pareto Charts, ANOVA, etc.), to better understand
problems, their root causes and determine solutions.
STATISTICAL PROCESS CONTROL (SPC): the use of statistical techniques such as
control charts to analyze a process or its outputs to take appropriate actions to achieve
and maintain a state of statistical control and to improve the process capability.
SUB-COMPONENT: one or more parts that when assembled together results in the EndItem Assembly or module.
SUB-TIER SUPPLIER: see TIER 2 (& LOWER) SUPPLIER.
SUPPLIER READINESS EVALUATION (SRE) RUN: the first documented build attempt by
the Supplier following installation, setup, and tryout of the production equipment and
tools. The Supplier Readiness Evaluation Run shows that the process is set-up,
debugged, and ready for a Production Demonstration Run during the PSO On-Site Visit.
The Supplier Readiness Evaluation Run and analysis provides the Supplier with the
opportunity to optimize and refine the process. The Supplier, with the concurrence of the
DCC PSO Team, will determine the quantity of parts that are completed during this run.
The purpose of the SRE is to provide pre-production data that confirms the proper set-up,
operation, and performance of the installed production line. Data collected during this
run typically include measurement data, machine cycle times, operation times, quantity
attempted, quantity accepted, etc. From this data, estimated production rates, FTC,
yields, and PP and PPK for special characteristics are calculated. There are no minimum
requirements for process performance, FTC, yields, or other indicators at this time. The
DCC PSO Team will evaluate the data from this run when deciding whether to schedule
the PSO On-Site Visit.
SUPPLIER TOOL RECORD (STR): A form generated by the creation of a new TPO (Tool
Purchase Order) requiring the identification of Supplier, or DaimlerChrysler owned
tooling, affected by the TPO.
108
SUPPLY CHAIN: includes all Suppliers used in producing a given part; from tier one to
the source of production materials.
SUPPLY CHAIN MAPPING: a method used to look at the complexity of the extended
enterprise value chain. Mapping details the manufacturing process, transportation and
other factors that go into component production.
TAKT TIME: The time in which one vehicle, assembly, or part (the item of interest) is to
be made.
TAKT Time
Net Operating Time Per Shift

Customer Re quirements in Units of Pr oduction Per Shift
TIER 1 SUPPLIER: a Supplier who is responsible for providing components, services, or

raw material directly to DaimlerChrysler. All references to Supplier in this manual refer
to a Tier 1 Supplier, unless otherwise specified. Note that in the case of some modules,
the Supplier of a module component may be treated as a Tier 1 Supplier, even though
they do not ship directly to DCC.
TIER 2 (& LOWER) SUPPLIER: a Supplier who is responsible for providing components,
services, or raw material to another Supplier in the Supply Chain. A Tier 2 supplies a Tier
1, a Tier 3 supplies a Tier 2, and so on. All references to sub-tier or sub-tier supplier
in this manual refer to a Tier 2 (or lower) Supplier, unless otherwise specified.
VERIFICATION SAMPLES: samples created with known defects in order to verify the
performance of Error and Mistake proofing. Verification samples must be clearly marked
and/or identified to prevent shipment to the customer and properly controlled to prevent
degradation and ensure relevance.
WORK IN PROCESS (WIP): product that has not gone through the entire production
process or is incomplete in some way.
109
110
INDEX
Page(s)
Advance Quality Planning (AQP) ........................................................... 2, 3
A Approval ..................................................................................................... 3, 4, 37, 43, 97
Bar Code Labeling.....................................................................................40
BSR/NVH ................................................................14, 16, 44, 89, 100, 104
Capability Matrix ......................................................................................63
Chrysler Development System (CDS) .............................14, 16, 20, 100, 107
Comments Sheet .................................................................................................................50
Control Plan .......................................... 12, 18-19, 22, 23, 29, 30, 35, 41, 44, 89, 90, 100-101
Daily Tooling Capacity ........................................................................37, 60
Design FMEA ........................................................................................14, 18, 29, 31, 89, 102
Documentation Checklist .....................................................................46-48
DVP&R ........................................................................................... 12, 15, 18, 29, 44, 89, 102
Electro-Static Discharge (ESD) Guidelines .................................................25
Element Requirements.....................................................................................................11-44
Error and Mistake Proofing .......................................................... 31-33, 90, 91, 102, 104, 108
Error and Mistake Proofing Requirements for Electrical Components .....................................33
Error and Mistake Proofing Requirements for Modules/Sequenced Part Delivery....................33
First Production Shipment Certification (FPSC) ................................................ 30, 90, 96, 103
First Time Capability (FTC) ..........................................................1, 19, 37, 38, 67-77, 95, 103
First Time Capability (FTC) Calculation Examples....................................67-77
Forever Requirements .....................................................................................................81-86
Frequently Asked Questions ................................................................93-98
Gage and Test Equipment Evaluation........................................................41
Gage R&R........................................................................... ..38, 41, 91, 103
Glossary .................................................................................................................99-109
IAA ........................................................ 3, 4, 95, 103
Incoming Material Certification Plan..........................................................22
Initial Process Study................................................................................ 29, 43, 56-57, 92, 97
Internal PSO Requirements ..................................................................88-92
Layered Process Audit .........................................................................34, 64
Lot Acceptance Sampling Table ............................................................................................62
Measurement System Report ............................................................................... 29, 35, 58-59
N Approval ...........................................................................................................................4
Net Operating Time for DCC Parts ................................................... ..37, 104
Operating Instructions .........................................................................26-27
Outgoing Material Inspection Plan.............................................................23
Packaging Approval...................................................................................39
Part Inspection Standard ................................................................................................ 22, 23
Part Number, Description, & Change Level.......................................................................12-13
Parts Handling Plan .............................................................................24-25
Parts Packaging and Shipping Specifications ........................................39-40
Powerway.com .......... ..3, 4, 7, 8, 9, 10, 20, 21, 34, 35, 46, 82, 94, 95, 96, 97
Process Performance Indices (PP, PPK) ........................................... 35, 38, 43, 63, 95, 105, 108
PPAP ................................................ 1, 2, 3, 4, 5, 8, 9, 20, 22, 38, 82, 90, 94, 98, 103, 16-107
Pre-PSO Documentation Review..................................1, 2, 3, 5, 7, 30, 35, 37, 41, 43, 105, 106
Preventive Maintenance ............................................................................42
Problem Solving ...................................................................................20-21
Process Flow Diagram and Manufacturing Flow Chart ...............................17
Process FMEA ........................................................................... 12, 16, 18, 29, 31, 44, 89, 106
Process Sign-Off Flowchart .....................................................6, 8
Process Sign-Off Responsibilities ...................................................7, 9
Process Sign-Off Strategy ............................................................5
Production Demonstration Run (PDR) ..............1, 3, 37, 38, 43, 53-55, 80, 92, 96, 97, 103, 106
111
Production Validation (PV) Testing ................................................................. 5, 44, 92, 95, 96

PSO Checklist...........................................................................................49
PSO Extended Run ..........................................................................................................79-80
PSO On-Site Visit .......... 1, 3, 4, 5, 7, 8, 9, 10, 21, 24, 28, 34, 35, 36, 37, 38, 97, 105, 106, 108
PSO Team Members................................................................................................................2
Quality Planning ..................................................................................20-21
Reference Manuals ........................................................ .98
Rework and Repair Instructions and Procedures...................................26-27
Safety Characteristics ..................................................................29-30, 107
Special Characteristics ....................... ..14, 16, 17, 18, 19, 26, 29-31, 34, 35, 36, 41, 43, 108
Supplier Readiness Evaluation (SRE) ...................................... ..2, 5, 35, 108
Supply Base Management .........................................................................20
Test Sample Sizes & Frequencies...............................................................15
Third (3rd) Party Sources .....................................................................41, 42
Tooling, Equipment, & Gages Identified .....................................................28
Z Approval ......................................................3, 4, 97
112
PSO 5.5 EDITION CHANGE LOG

REVISION
DATE
12/2006
SECTION
Entire Document
DESCRIPTION OF CHANGE
Initial Revision
113
84-231-1227 (REV. 12/2006) DaimlerChrysler Corporation
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Process Sign-Off (PSO)

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PROCESS SIGN-OFF (PSO)

Mgr - AQP Strategy & Processes

AQP Strategy & Processes

AQP Strategy & Processes

AQP Strategy & Processes

Process Quality Engineering

Supplier Quality - Graz

ASQP - AQP/PSO University

Supplier Quality - Mexico

Requests for revisions or changes to the manual

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Process Sign-Off (PSO)

PROCESS SIGN-OFF DEFINITION

WHY IS A PSO NECESSARY?

WHO CONDUCTS THE PSO?

WHEN IS THE PSO PERFORMED?

Start, an Interim Approval Authorization (IAA) is required. For specific requirements

HOW IS THE PSO PERFORMED?

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PROCESS SIGN OFF STRATEGY

PSO TEAM CONDUCTS

SUPPLIER SUBMITS PPAP

SUPPLIER COMPLIES WITH

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PROCESS SIGN-OFF FLOWCHART

Self Directed AQP

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PSO On-Site Visit

PSO "A" disposition &

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Supplier submits PPAP

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PSO ELEMENT REQUIREMENTS

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PART NUMBER, DESCRIPTION AND CHANGE LEVEL

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PART NUMBER, DESCRIPTION AND CHANGE LEVEL, CONT.

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TEST SAMPLE SIZES AND FREQUENCIES

3.4.1 Deviations from the Performance Standards shall be

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4.2.1 This procedure shall be reviewed periodically for effectiveness

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PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN

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CONTROL PLAN & PROCESS MONITORING

6.1.2 Repair/rework stations shall have controls equivalent to

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