STANDARD N10 039 - Magna · PDF fileMSF - STANDARD N10 039 Edition Date 09.08.2007 ... PPAP...

STANDARD

MAGNA STEYR Fahrzeugtechnik AG & Co KG

N10 039

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Supersedes VAB 13.03.05

Process Sign Off PSO

Professional Responsibility 13.07.2007 Head of CoC SQA&D F. Zach Prepared in accordance with specification N10100-1, N10100-2 / Formal – Release: A. Weinzerl, 09.08.2007 The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design

This form is assigned to N10100-1

MSF - STANDARD N10 039

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Purpose Process Sign-Off must be performed on all new or modified parts, parts which have been out of production for 12 months or more, or parts with historical high warranty or quality problems. All parts that have a high Initial Risk Evaluation (IRE) VAB 13.03.07 must have a MAGNA STEYR Fahrzeugtechnik led PSO. Parts with a medium IRE must have a MAGNA STEYR Fahrzeugtechnik led PSO and a Supplier led APQP (Advanced Product Quality Plan, refer to APQP manual). Parts with a low IRE must have a Supplier led PSO to establish production readiness. Any product or process change that occurs during the lifecycle of a part or system must be reviewed by the PSO Team to determine whether re-PSO is required based on the Risk Drivers. Revisions since previous version First edition Correlation to the Process This standard is assigned to the process PZB-13.00.00 “Einkaufsprozesse” Documents quoted N85 062 Produktionsprozess- und Produktfreigabe N85 065 Qualitätsmanagement – Forderungen an Lieferanten MSA AIAG Measurement Systems Analysis SPC AIAG Statistical Process Control PPAP AIAG Production Part Approval Process References in the text will be as follows: N85 000 “Working Instructions” (AA) or “Process descriptions” (PZB) quoted in the standard are only for internal usage.


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Index

1 SIX W´S OF PROCESS SIGN-OFF: 4

2 PROCESS SIGN-OFF (PSO) INSTRUCTIONS: 5

2.1 Pre-PSO Meeting: 6

2.2 PSO On-Site Visit (Demonstration run at Supplier manufacturing facility): 7

2.3 Form/Data Retention: 7

3 PROCESS SIGN-OFF (PSO) CHECKLIST: 8

3.1 PRE-PSO MEETING DATE: 8

3.2 DOCUMENTATION (APPROVAL COLUMN) 8

3.3 PROCESS (APPROVAL COLUMN) 8

3.4 FPSC REVIEWED WITH SUPPLIER 8

3.5 ALL PROCESS SIGN-OFF ELEMENTS APPROVED (Status GREEN) 9

3.6 CORRECTIVE ACTION REQUIRED (Status YELLOW) 9

3.7 ON-SITE REVISIT REQUIRED (Status RED) 9

3.8 SIGNATURE BLOCK 9

4 PROCESS SIGN-OFF (PSO) DOCUMENTATION: 10

4.1 PSO Checklist 10

4.2 Checklist Element & Instructions: 11

5 GLOSSARY: 26

6 FREQUENTLY ASKED QUESTIONS: 32


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1 Six W´s of Process Sign-Off: WHY: Process Sign-Off is a method to verify that a Supplier’s quality planning processes

have been successfully executed and that its production processes are capable of producing quality parts in sufficient quantity for production.

WHAT: Process Sign-Off is a systematic and sequential review of the Supplier' planned and actual manufacturing process at the quoted peak daily line rate, including manpower, facilities, equipment, material, methods, procedures, software level, and tooling. The MAGNA STEYR Fahrzeugtechnik approach to verification is composed of four items, which collectively ensure that the Supplier’s system is acceptable and results in quality products. First, documentation ensures that the company methods of operation are recorded and available for all employees to reference. While important for training new employees, it also serves the experienced employee who encounters infrequent situations or changes. Second, there is no substitute for observing an operation first hand. Therefore, it is a requirement that PSO teams witness a build as part of the MAGNA STEYR Fahrzeugtechnik PSO process. The team must witness at least one build using production tools. The run must produce product that meets the quality and production rate requirements of MAGNA STEYR Fahrzeugtechnik Corporation. Third, data analysis provides measures of quality for the production system. Observing a build will reveal extreme bottlenecks and inefficiencies, but data collection, analysis, and summarization are the real measures of part quality and production efficiency. Production measurements will provide the production rate, First Time Capability (FTC), takt time and other statistics that validate the Supplier’s ability to produce the product quantities required by MAGNA STEYR Fahrzeugtechnik Corporation. Finally, testing of the production parts will validate the Supplier’s system and provide evidence that the part meets the engineering, quality, durability, and reliability requirements contained in the performance, process, and material specifications. In summary, PSO assures that the Supplier has exhibited performance that justifies a Production Part Approval Process (PPAP) warrant submission.

WHO: PSO Team members (minimum of Supplier Quality Specialist, Engineer, Buyer, Supplier, and other appropriate representatives).

WHERE: A Pre-PSO Meeting for document review is required followed by a PSO On-Site Visit conducted at the Supplier's manufacturing plant. Additional PSO On-Site Visits may also be conducted at the sub-tier 1 suppliers manufacturing plants if the PSO Team determines it is required.

WHEN: The Process Sign-Off Production run should be scheduled by the PSO Team following the Pre-PSO Meeting when the PSO Team agrees that:

• All required Supplier documentation has been reviewed and is acceptable. • Production tooling is complete, finalized, on-site at the Supplier's plant, has

been set-up and debugged, and the Supplier Readiness Evaluation Run is complete with the results documented.

• The production process is in place, has been debugged, preliminary performance has been determined, and the Supplier is ready for the Production Demonstration Run. This run is based upon a predetermined sample size and line speed.

• The production operators are trained and capable of running at the contracted peak and sustained line speed calculated as: Line speed required [pieces per hour] = quoted tooling/equipment capacity [pieces per day] divided by quoted net operation time [hours per day]


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The purpose of PSO is to demonstrate Supplier process capability. The requirement is to complete all PSO’s prior to supplying parts for sellable vehicles. If the PSO is not complete prior to build of sellable vehicles an Interim Approval Authorization (IAA) is required. Parts made during the PSO demonstration run may be used for PPAP if and only if PPAP requirements including the statistical requirements have been successfully completed. Refer to the Production Part Approval Process (PPAP) manual. Reference manuals and sources are described in the Publication Appendix of this manual.

HOW: Use the Process Sign-Off Checklist. Pre-PSO Meeting:

The PSO Team must review the PSO documentation prior to scheduling the PSO Production Run.

Process Sign-Off On-Site Visit: The PSO Team must complete the 20 elements of the PSO Checklist at the Supplier’s manufacturing facility.

PSO verifies the dimensional, material, performance, and production capability of the component.

2 Process Sign-Off (PSO) INSTRUCTIONS: The MAGNA STEYR Fahrzeugtechnik Supplier Quality Specialist will initiate the PSO dialogue with the PSO Team, schedule and coordinate Pre-PSO Meetings and PSO On-Site Visits. The Supplier Quality Specialist will also advise the Supplier of the documentation the team will want to review. Unless otherwise directed, the documentation should be delivered to MAGNA STEYR Fahrzeugtechnik no later than 2 weeks before the Pre-PSO Meeting. The recommended method for presenting documentation to the MAGNA STEYR Fahrzeugtechnik PSO Team is in a binder with dividers that correspond to each Checklist element. Documentation required for each element would be placed in that section. If the element pertains to more than one section, only one copy is required in the binder. Other sections will refer to the section containing the document copy. English and German are the official corporate languages of MAGNA STEYR Fahrzeugtechnik. At a minimum the Control Plan has to contain either English or German text.


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2.1 Pre-PSO Meeting: Review program status

To reduce the time spent at the Supplier's facility, the PSO Team shall review and approve all

PSO Checklist elements and available documentation with the Supplier prior to the PSO On-Site Visit.

1. It is important that the Supplier Readiness Evaluation Run results for Element 18 and Production Demonstration Run plans for Elements 19 and 20 are reviewed.

2. Element 18 - the Supplier is required to present the performance results obtained from a (usually 30 pieces) Supplier Readiness Evaluation Run. The Supplier with the concurrence of the MAGNA STEYR Fahrzeugtechnik Supplier Quality Specialist will determine the exact quantity. This run shows that the process is set-up, debugged, and ready for the Production Demonstration Run during the PSO On-Site Visit.

3. Element 19 - the PSO Team must review the plan for required production rates, data to be recorded, recording method, measurement method, and calculations to be performed for each station, the overall production line, multiple production lines and multiple tools.

4. Element 20 - the PSO Team must review the Initial Process Study plan for each characteristic and tolerance designated as a "Special" characteristic, as well as those additional characteristics and operations selected by the Team for initial process studies. The Team should review the inspection methods, gage calibration and (Measurement Systems Analysis) MSA results, the data to be recorded, the data recording methods, the quantity to be inspected, and the calculations to be performed.

5. These reviews shall be completed before the PSO On-Site Visit is scheduled. This will expedite the on-floor assessment.

6. Emphasize that this is a team effort to verify production readiness and process capability.

Review all of the elements and requirements from the PSO Checklist with special emphasis on the following items:

Review applicable engineering standards, product material, process methods and inspection procedures, preliminary process performance studies and drawings to confirm test frequencies and procedures to be used in compliance with APQP and Purchase Order requirements.

Review Error and Mistake Proofing methods and implementation. Review product and process characteristics and identify the characteristics that will be

measured during the PSO On-Site Visit. These are not limited to special characteristics. The PSO Team may select any characteristics of interest in addition to special characteristics.

Review the Packaging Plan including back-up expendable packaging. Review the Control Plan. Set the PSO On-Site Visit date and agenda. Verify the planned line speed for the PSO Production Demonstration build. Review requirements of First Production Shipment Certification (FPSC) program with the

Supplier. When complete, indicate on the PSO Checklist that the review has been done and the date reviewed.

Discuss the Quoted Line Speed, Quoted Customer Tooling Capacity, Quoted Net Operating Time for Customer Parts, required yield and intended part usage with the Supplier and Buyer during the Pre-PSO Meetings.


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The PSO Team should know the line speed the Supplier will be required to demonstrate before the PSO On-Site Visit is scheduled.

2.2 PSO On-Site Visit (Demonstration run at Supplier manufacturing facility): Begin and end the PSO On-Site Visit by meeting with the appropriate plant management

personnel to discuss the purpose of the visit and the results of the on-floor assessment. The majority of the time should be spent on the plant floor observing the manufacturing process and reviewing the plant's production readiness.

Verify that all process instructions and Control Plan checks are being effectively implemented. (Example: Operator Instructions, Gage Inspection Instructions and process improvements.)

Review opportunities for Error and Mistake Proofing and process improvements during the on-floor assessment.

Review process performance: o Gage R & R studies must be completed on all measurement systems prior to capability

evaluation. o PP and PPK >= 1.67 must be achieved and documented for each special characteristic o Unacceptable preliminary performance results require a written recovery plan.

Reinforce to Supplier plant personnel that they cannot change the approved process without prior notification and written approval by MAGNA STEYR Engineering, and Supplier Quality. This includes Continuous Improvement Workshop Floor Exercises, sub-source changes, and sub-source process changes. .

Each product where MAGNA STEYR Fahrzeugtechnik leads the PSO must have a First Production Shipment Certification (FPSC) program. This program should be reviewed again in detail with the Supplier's plant personnel N85062. Following this review, the PSO Team should indicate that the review took place and enter the appropriate date on the PSO Checklist form.

2.3 Form/Data Retention: The Process Sign-Off Checklist shall be used to document the Process Sign-Off information. The form in this manual may be duplicated as needed. The Supplier and Magna Steyr have to be retained all Process Sign-Off documents for the volume production period of the production material affected, plus one year. N85062


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3 Process Sign-Off (PSO) CHECKLIST:

3.1 PRE-PSO MEETING DATE: The MAGNA STEYR Fahrzeugtechnik Supplier Quality Specialist will contact the Supplier to set a meeting date for a review of the Supplier's documentation. At that meeting, the PSO Team will review the documentation and any required corrections with the Supplier. Deficiencies may require additional Pre-PSO Meetings. The PSO Team must determine that all the documentation is acceptable before scheduling the PSO On-Site Visit. NOTE: Minor documentation corrections can be reviewed and accepted during the PSO On-Site Visit.

3.2 DOCUMENTATION (APPROVAL COLUMN) Each category of the PSO Checklist must be supported with documentation and reviewed by the PSO Team prior to visiting the Supplier's manufacturing plant. Before the PSO On-Site Visit the PSO Team shall "check-off" the appropriate PSO Checklist boxes for the DOCUMENTATION (element 1 through element 20) as defined below: ACCEPT: When the Supplier has presented documentation to support the line element

requirements, check the appropriate ACCEPTABLE (ACCEPT) box. UNACCEPT: Supporting data and documentation must be sufficient to meet the line element

requirements. If any supporting documentation is insufficient or inadequate, then check the UNACCEPTABLE (UNACCEPT) box.

3.3 PROCESS (APPROVAL COLUMN) During the PSO On-Site Visit the PSO Team shall "check-off" the appropriate PSO Checklist boxes for the PROCESS as defined below: ACCEPT: If the PSO Team witnesses the production process and agrees that the line

element requirements have been met and are effectively implemented, check the appropriate ACCEPTABLE (ACCEPT) box.

UNACCEPT: If the PSO Team witnesses the production process and agrees that the element

requirements have not been met, or have not been effectively implemented, check the appropriate UNACCEPTABLE (UNACCEPT) box.

3.4 FPSC REVIEWED WITH SUPPLIER The PSO Team shall review the FPSC requirements with the Supplier during the Pre- PSO Meeting, and again during the PSO On-Site Visit. Following the discussion with the Supplier's plant personnel, the PSO Team will check "YES", and record the review date in the appropriate field on the PSO Checklist. Each PSO led by MAGNA STEYR Fahrzeugtechnik must have a FPSC review. PSO ON-SITE VISIT DATE / NUMBER The PSO Team will enter the PSO On-Site Visit date and number in the "PSO ONSITE VISIT DATE / NUMBER" field. If this is the first PSO On-Site Visit, enter a one, if this is the second, enter a two, etc.


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3.5 ALL PROCESS SIGN-OFF ELEMENTS APPROVED (Status GREEN) Check the appropriate box after completing PSO Checklist elements 1 to 20. All PSO elements must be approved prior to full PPAP submission. If shipments are required prior to full PPAP approval, an Interim Approval Authorization will be necessary. YES: Means that all PSO Checklist elements are acceptable for both DOCUMENTATION and

PROCESS. The PSO is approved. NO: Means that at least one PSO Checklist element is unacceptable. The PSO is NOT

APPROVED.

3.6 CORRECTIVE ACTION REQUIRED (Status YELLOW) Indicate whether any corrective action is required for this PSO and enter the completion date for the corrective action. A detailed description of the discrepancy and corrective action should be entered in the on-line (Quality Platform) QPF.

3.7 ON-SITE REVISIT REQUIRED (Status RED) The PSO Team will determine if a re-visit is needed to achieve PSO approval. The Team will mark the appropriate box and enter the intended re-visit date. In some cases, the Supplier will need additional time to assess the extent of the required corrections before a re-visit date can be proposed. In that case, indicate the re-visit date is "TBD by…" and enter the date by which the Supplier will be able to propose a re-visit date. Re-visits require that new PSO Checklist forms be initiated. Previously accepted Checklist elements need not be repeated. Only those elements that were originally judged unacceptable need be reviewed and rated. A copy of the prior PSO forms must be attached to document the previously accepted elements.

3.8 SIGNATURE BLOCK The MAGNA STEYR Fahrzeugtechnik PSO Team members and the Supplier representatives must print their names in the appropriate PSO Checklist fields, then sign and date the Checklist. Doing so indicates the signers' approval of all PSO forms.


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4 Process Sign-Off (PSO) DOCUMENTATION:

4.1 PSO Checklist


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4.2 Checklist Element & Instructions: PROCESS SIGN-OFF CHECKLIST REQUIREMENTS

Checklist Element & Instructions Documentation 1) PART NUMBER, DESCRIPTION AND CHANGE LEVEL Verify that the documents listed have the correct part number, description, and change level entered or cross-referenced. A procedure must be in place to assure correct part number and revision level as changes occur. Where the product identity is not inherently obvious, the Supplier must employ an internal numbering system and provide a cross reference which enables users to identify the MAGNA STEYR Fahrzeugtechnik part number and revision which corresponds to the Supplier's numbering and revision system.

• Engineering standards • CATIA files, drawings, and other

relevant documents • Software level

Additional documents that must indicate part number and revision level:

• Design and Process FMEA’s (refer to element 6)

• Control Plan (refer to element 7) • Set-up sheets, operator instruction

sheets, and inspection instructions (refer to element 11)

• Shipping audit sheets (refer to element 13)

2) ENGINEERING STANDARDS IDENTIFIED All applicable engineering standards with the latest change level must be identified, listed, and available. A system must be in place to obtain revisions to the standards and to notify all applicable departments of specification changes as they occur.

• List of applicable engineering standards

3) SPECIAL PRODUCT AND PROCESS CHARACTERISTICS IDENTIFIED A list of special product and process characteristics such as key, safety, noise, etc., must be developed using MAGNA STEYR Fahrzeugtechnik input as well as Supplier knowledge of the product and process. The design and process FMEA’s should be used to help create this list. Special Characteristics require either SPC reporting that must be made available to MAGNA STEYR Fahrzeugtechnik representatives upon request or sorting against tolerance windows reduced based on MSA-results.

• Special characteristics list

Additional documents that must indicate special product and process characteristics:

• DFMEA and PFMEA (refer to element 6)

• Control Plan (refer to element 7) • Set-up sheets, operator instructions

(refer to element 11)


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PROCESS SIGN-OFF CHECKLIST REQUIREMENTS Checklist Element & Instructions Documentation 4) PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN The process flow diagram must represent the entire manufacturing process from receiving through shipping operations and should include the following: Processing sequence, method, and

equipment used at each station including inspection and repair/rework stations.

Number of operators needed per station including inspection and repair/rework stations.

It should include both main-line assembly processes as well as all off-line processes that supply it. The manufacturing floor plan should show the layout of the facility and illustrate station-by-station the overall flow of the manufacturing process.

• Process flow diagram • Manufacturing floor plan

5) TOOLING, EQUIPMENT, AND GAGES IDENTIFIED All tooling, gages, fixtures, and capital equipment required to produce a product must be identified, tagged, and appear on a tooling list All tooling, gages, test fixtures, and test equipment used in the manufacturing process from laboratory, production, tool room, maintenance and quality areas must be identified in the Supplier’s maintenance, storage, and calibration programs. Any temporary or interim tooling or equipment must be included in the tooling list.

• Tooling list • Supplier Tool Record (STR)


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PROCESS SIGN-OFF CHECKLIST REQUIREMENTS

Checklist Element & Instructions Documentation 6) DESIGN FMEA AND PROCESS FMEA Design and process FMEA's must be completed for each unique product or process and must be approved by the PSO Team. All FMEA concerns must have descriptions of current controls and recommended actions. Buzz - Squeak - Rattle (BSR) and Noise - Vibration - Harshness (NVH) issues should be addressed in the DFMEA and/or PFMEA. The DFMEA and PFMEA are living documents and must be traceable to the engineering change levels and processing changes. These documents should contain the special characteristics agreed to by the PSO Team from element 3. The Process FMEA (PFMEA) must reflect the entire manufacturing process from receiving through shipping. Note: In instances where the Design or Process FMEA is the responsibility of MAGNA STEYR Fahrzeugtechnik and the document is incomplete, a comment should be entered on the QPF stating the document that is incomplete and identifying the MAGNA STEYR Fahrzeugtechnik responsible individual and completion date. PSO approval should not be withheld.

• DFMEA • PFMEA


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Checklist Element & Instructions Documentation 7) CONTROL PLAN The Control Plan must describe each step of the manufacturing process including: receiving, material handling and storage, in-process operations, testing, inspections, rework/repair, and shipping. Refer to the Advanced Product Quality Planning and Control Plan manual. All process and product control parameters should be documented. Sample sizes, frequency of inspection, acceptance criteria, and reaction plans must be included. The Control Plan is a living document and must be updated to reflect any changes to the manufacturing process. All critical product and process characteristics that describe materials, processes, performance, reliability, quality, and/or design requirements should be included. Any temporary or interim off-standard operation must be identified. All changes that occur anywhere in the Supply Chain that potentially affect the process, part quality or part supply must be approved in writing by MAGNA STEYR Fahrzeugtechnik. An authorization letter identifying the change and effective date signed by the appropriate MAGNA STEYR Fahrzeugtechnik Product Engineer, Supplier Quality Specialist, and Buyer is the acceptable format.

• Control Plan


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Checklist Element & Instructions Documentation 8) TEST SAMPLE SIZES AND FREQUENCIES Products covered under an Engineering Standard that specifies test sample sizes and test frequencies must have these testing requirements included in a Design Verification Plan and Report (DVP&R) test plan.

• DVP&R • Applicable Engineering standards

9) GAGE AND TEST EQUIPMENT EVALUATION All gages and test equipment shall be calibrated, reflect the last calibration date and expiration date. Calibrations must be traceable to a known source/ standard. All gages must have acceptable MSA performed in conjunction with the Supplier Readiness Evaluation Run (SRE) prior to the Pre-PSO Meeting. MSA-studies must be performed according to the Measurement Systems Analysis (MSA) manual for both attribute and variable gages. MSA

• MSA records • Gage and test equipment calibration

records

10) ERROR AND MISTAKE PROOFING "Error Proofing" and "Mistake Proofing" approaches used to improve the production process must be reviewed during the Pre-PSO Meeting and verified during the PSO On-Site Visit.

• Error proofing eliminates by design the possibility of producing a specific defect.

• Mistake proofing identifies errors and prevents them from becoming non-conformances.

• List of error and mistake proofing implemented by operation number

• Error and mistake proofing studies


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Checklist Element & Instructions Documentation 11) PROCESS MONITORING AND OPERATING INSTRUCTIONS Operator, set-up, and inspection instructions must be approved, signed, dated, traceable to the level of parts being produced, and must include documented sample sizes and frequencies. The instructions must be located adjacent to the process, visible to the operator and legible. Visual displays and diagrams should be used whenever possible. Special characteristics must be addressed in the instructions. The instructions must enable any adequately trained person to perform the described operation. Process control charts (attribute or variable) must be available and be reviewed by the PSO Team.

• Operator instructions • Set-up sheets • Inspection instructions • Visual displays • Control charts


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Checklist Element & Instructions Documentation 12) INCOMING AND OUTGOING MATERIAL QUALIFICATION/CERTIFICATION PLAN Review the Incoming and Outgoing Material Qualification/Certification Plan plus associated documents and records. The plan must be verified during the PSO On- Site Visit.

• The plan must describe operations and procedures used by incoming and outgoing inspection to qualify and certify incoming material and outgoing product.

• Some parts require lot control and traceability that must be described in detail and verified. For those parts Product identification and traceability must be maintained and recorded through all stages of production, delivery and installation. At a minimum, record keeping which tracks the usage of lots or batches back to the production date. Parts should be marked with Supplier Code, Part Number and Run, if applicable.

• A lot is not to exceed one shift or one day's production, whichever is smaller.

• Special controls are required for reworked or repaired material to provide traceability to the rework or repair process.

• The plan must address containment of non-conforming material.

• The plan shall identify processes performed by sub-suppliers or any outside processor and must include records indicating inspection/test results that relate to the appropriate lot code.

• The lot acceptance date (or date the lot was inspected) must be identified by the year, month, day and numeric sequence.

• Components or production materials used in the assembly of parts for MAGNA STEYR Fahrzeugtechnik must have full approval status. The PSW from sub-tier suppliers must be on file.

• Incoming and outgoing inspection procedures.

• Receiving and shipping reports • Routing cards/sheets • Material standards • Inspection/test reports • Copies of sub-tier supplier certifications

for each specific component including a copy of the PSW (Part Submission Warrant)


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PROCESS SIGN-OFF CHECKLIST REQUIREMENTS Checklist Element & Instructions Documentation 13) PARTS PACKAGING AND SHIPPING SPECIFICATIONS The parts packaging and shipping plan must include the types of containers (expendable or returnable) that will be used to ship product to MAGNA STEYR Fahrzeugtechnik. The plan must include:

• Specific container information (returnable and/or expendable, container dimensions, container material, # of pieces per container, weight of full/empty container, # of containers per pallet, etc.).

• Shipping and labelling instructions, and packaging requirements.

The dunnage design and test pack must be approved by the MAGNA STEYR Fahrzeugtechnik receiving facility. If MAGNA STEYR Fahrzeugtechnik designed dunnage is used, the Supplier is not responsible for Receiving Facility approval. Laboratory tests and shipping tests must be documented including the results. Expendable and returnable containers must be tested using simulated or actual shipping routes prior to PSO. Refer to the MAGNA STEYR Fahrzeugtechnik Packaging and Shipping Instructions.

• Parts packaging and shipping plan. • Shipping instructions (incl. Transmittal

of container style, type, etc.). • Laboratory Test Results • Shipping Test Results • Returnable Container Management

Plan including: • Maintenance and cleaning • Backup expendable plan, where

applicable • Bar coded labelling instructions #13 Continued on next page.


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Checklist Element & Instructions Documentation If returnable containers are to be used, a Returnable Container Management plan must be developed which includes:

• Inventory control to track the number of containers on hand and in transit.

• Documented procedure for the mandatory transmittal of container/part number information during Advanced Shipping Notification (ASN) submissions from the Supplier's facility.

• Maintenance plan, which identifies damaged or contaminated containers for removal from service and previsions for repair and cleaning.

• Expendable backup plan must cover a shortage of returnables. The backup plan must define the expendable packaging and the implementation of this packaging until returnables are available. Expendable backup packaging must be available, at all times, in the event of a shortage. Backup packaging must maintain the same footprint (dimensions) as the returnable container, and where possible, hold the same number of pieces.

• Both expendable and returnable packaging should be sized to meet the “two-hours-of assembly- plant-production” per container, maximum. Deviation from this requirement requires concurrence from MAGNA STEYR Fahrzeugtechnik SQA.

• Shipping and labelling instructions must conform to Packaging and Shipping Instructions.

• Bar coded labels must reflect the latest change level.

• The date and sequence code must be displayed in the “manufacturing date space” of the prescribed shipping container label.


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Checklist Element & Instructions Documentation 14) PARTS HANDLING PLAN The Parts Handling Plan must include the following:

• Documented procedures that detail the internal material handling operations. The types of containers used throughout the manufacturing process including any external processing. Note: MAGNA STEYR Fahrzeugtechnik does not procure returnable containers for supplier’s WIP (Work in Process) or sub-tier suppliers. Containers for these components are the responsibility of the Supplier. Use of MAGNA STEYR Fahrzeugtechnik containers for this purpose is considered misappropriation of corporate assets. If the PSO Team detects a container violation during the PSO On-Site Visit, element 14 on the Checklist should be marked REJECT in the Process column and an action added to the QPF.

• The method by which material is tracked and transferred from one point to another, such as routing cards.

• Where production operators must use special handling methods, appropriate instructions should be included in the operating instructions.

• Material handling procedures • Packaging instructions Additional

documents that must indicate parts handling instructions:

• Operating instructions (refer to element 11)

• Routing cards/sheets (refer to element 12)

15) PREVENTIVE MAINTENANCE PLANS A Preventive Maintenance (PM) plan must exist for all equipment and tooling. As a minimum the PM plan must include:

• Set-up and approval procedures for the installation, set-up, and adjustment for machines, tools, and other equipment.

• Plans, schedules, frequencies, and instructions for the periodic maintenance of equipment or machinery, tools, dies, patterns, fixtures, etc., for each item of process equipment and tooling.

• Perishable tools and supplies, etc., shall have life expectancy and utilization parameters identified including maintenance frequency and responsibility.

• PM Plan


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Checklist Element & Instructions Documentation 16) QUALITY PLANNING Quality Planning must translate MAGNA STEYR Fahrzeugtechnik’s Product Creation Process (“Project Guideline” PGL) into product and process design requirements. The plan must identify major milestone events, required product or process tasks, responsible organizations, and scheduled and actual timing dates. Refer to the Advanced Product Quality Planning and Control Plan (APQP) manual and MAGNA STEYR Fahrzeugtechnik’s PGL Manual. The first tier Supplier is responsible for conducting quality planning that includes their sub-suppliers. Quality planning must cascade through the supply chain. A diagram or indented list of the "supply chain" which reflects the Supplier/Sub-supplier hierarchy is required. The list must identify down to the production material level (or in some cases raw material level) each Sub-supplier by name, part or material produced, manufacturing plant location, and PPAP status of the parts supplied. Each Sub-supplier must be informed of the MAGNA STEYR Fahrzeugtechnik requirements.

• Advanced Product Quality Plan (APQP).

• Sub supplier source diagram and list with PPAP status of the parts supplied.

17) PROBLEM SOLVING METHODS Evidence of problem solving techniques must be provided describing how these techniques were used in developing the production process. Identify the individuals who participated in the problem solving process by name, title, and location.

Examples of Problem Solving Methods:

• DOE (Design of Experiments) • 7-Step/8D Corrective Action Plan • Root-Cause-Analysis • (Fishbone-)Charting


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Checklist Element & Instructions Documentation 18) EVIDENCE OF PRODUCT SPECIFICATIONS Prior to the Pre-PSO Meeting:

• The Supplier is required to present the performance results obtained from a Supplier Readiness Evaluation Run for each production line/tool. The Supplier with the concurrence of the MAGNA STEYR Fahrzeugtechnik Supplier Quality Specialist will determine the exact quantity (usually 30 pieces). This run shows that the process is set-up, debugged, and ready for a Production Demonstration Run during the PSO On-Site Visit.

• Process performance calculations (PPP and PPK) are required for each machine and operation as well as the overall process. In the case of multiple production lines/tools, process performance calculations are required for each line. These performance values will be used as an indication of the initial performance. No numeric requirements for FTC, yield, PP and PPK are imposed at this time.

• The Supplier Readiness Evaluation Run and analysis provides the supplier with the opportunity to optimize and refine the process.

• During the PSO On-Site Visit: • PSO Team members are required to

randomly select and measure, or witness the measurement of, specific product or process characteristics (other than those of the final product). 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 - Solderability, dimensional checks or reflow oven profile for an electronic printed wiring assembly - Selected dimensions or other parameters for a piece part used in a purchased assembly

• Supplier Readiness Evaluation (SRE)

Run results • Laboratory reports • Material Certifications


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PROCESS SIGN-OFF CHECKLIST REQUIREMENTS Checklist Element & Instructions Documentation 19) LINE SPEED DEMONSTRATION The Supplier must demonstrate to the PSO Team that they are capable of producing quality parts at the Quoted Customer Tooling Capacity based on the Net Operating Time for Customer Parts. The Production Demonstration Run must be on the production line(s) of record, using production tools, processes, and trained operators. The Production Demonstration Run consists of 300 pieces or six hours of production whichever is more stringent. For multiple production lines or tools this requirement applies for each production line/tool. The PSO Team has the authority to adjust the quantity of parts based on the parts complexity and cost. Any deviations from the minimum quantity of 300 pieces or two hours of production must be approved in writing by MAGNA STEYR’s SQA Management.

NOTE: Rework should not be included in the Product Demonstration count. The count should only include those components produced successfully. If the line is empty at the start of the Production Demonstration Run, line fill time should not be counted in the six-hour requirement. Count completed units only starting with the first completed unit off the production line.

The PSO Team must witness the PSO build and monitor the PSO Line Speed during the Production Demonstration Run and record the value. In the case of multiple production lines/tools, the line speed for each line/tool will be recorded and the production line identified. The PSO Team will also indicate on the form whether the production line is a "shared" line with additional production requirements for other MAGNA STEYR Fahrzeugtechnik (or other customer’s) products and will enter the CUSTOMER Tooling Capacity as well as the Total Tooling Capacity. If it is a shared line they will additionally enter Other Customer’s Capacity and Excess Capacity. .

• Line speed calculation • Process constraints and contingency

plans #19 Continued on next page


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PROCESS SIGN-OFF CHECKLIST REQUIREMENTS Checklist Element & Instructions Documentation Process studies must be performed using part data from the Production Demonstration build. Refer to Element 20. Process constraints (bottlenecks), which may impact quality or production schedules must be documented on QPF, and contingency plans established

20) INITIAL PROCESS STUDY Process performance studies (PP and PPK) must be performed for all special characteristics and other dimensions selected by the PSO Team, using part data from the Production Demonstration Run. For multiple lines/tools/cavities, the data from each one must be recorded separately and identified. PP and PPK must be calculated individually for each line/ tool/cavity (each process stream). The selected characteristic, tolerance, type (attribute or variable), quantity processed, quantity accepted, and calculated performance values must be recorded. It is intended that 100% of the parts from the Production Demonstration Run be included in the study. Where this is not practical, the PSO Team can deviate from the 100% requirement. However, at least 100 parts in 25 sub-groups must be checked from each production line/tool/cavity to satisfy PPAP requirements. The PSO Team must note any deviation from the requirements. For attribute studies, the performance calculations PP and PPK do not apply. Where SPC methods are planned, maintaining a history of the component production sequence, production line/tool and characteristic’s values enables post-run data investigations. Other calculations such as First Time Capability (FTC), station process quantities, takt rates, and accepted quantities must be included in the study and recorded. FTC is measured as the total number of items correctly processed, divided by the total number attempted. These calculations must be completed for each production line/tool. Correctly processed means no repairs are required or allowed. Repaired parts are not to be used in the FTC calculation. A recovery plan is required for all Special Characteristics that do not have a PPK of at least 1,67.

• Initial Process Study Plan and Results • First Time Capability (FTC) Study • Station process takt rates • Yield/Reject rates • End item part layout reports Additional

documents that must indicate process performance:

• Control charts (refer to element 11) #20 Continued on next page


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PROCESS SIGN-OFF CHECKLIST REQUIREMENTS Checklist Element & Instructions Documentation Any deviations from the PPK requirement must be approved in writing by the PSO Team. If Process Capability is less than the required PPK ≥ 1.67, then 100% verification of shipped parts is acceptable if the PSO Team agrees based on an Interim Approval Authorization. However, for variable gages, tolerances used for 100% verification must be reduced by the extent of MSA results. Example: A variable gage used to check a special product characteristic of 125±3 mm has an MSA result of 22% of product tolerance. That means the gage error can be up to 1.32 mm (±0.66 mm) for any given measurement. To ensure that non-conforming product is not accepted the acceptance limits must be reduced by 22% to 125±2.34 mm. If we assume that the gage can discriminate between fractional units of 0.05 mm, the tolerance used should be ± 2.3 mm. If the gage can discriminate between fractional units of 0.01 mm, the tolerance used should be ±2.34 mm. An alternative method for ensuring the acceptance of only conforming product is to repeat the measurement several times for a given part then average the results. Refer to the AIAG, Measurement Systems Analysis (MSA) manual, Appendix B, Reducing Variation Through Multiple Readings, for further explanation. Parts made during the Production Demonstration Run may be used for PPAP if and only if PPAP requirements including the statistical requirements have been successfully completed.


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5 GLOSSARY: AQP (Advanced Quality Planning): is a structured method of defining and establishing the required steps necessary to assure that a product satisfies the customer. Advanced Quality Planning embodies the concepts of defect prevention and continuous improvement as contrasted with defect detection. CAPABILITY STUDY: is a statistical analysis of the output from a machine or a process to determine its capability. This analysis is especially important when a new product is introduced so product quality and variation reduction can be assessed as a basis for continuous improvement. CATIA: is a computer aided three dimensional interactive applications design and manufacturing system. This software was developed and is maintained by Dassault Systems of France and is marketed in the United States by IBM. It is known as a CAD/CAM system. CHARACTERISTIC: is a unique feature of a product or process, or its output, from which variable or attribute data can be collected. CONTROL PLAN: are written descriptions of the systems for controlling parts and processes. They are written by suppliers to address the important characteristics and engineering 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. DFMEA (Design Failure Mode And Effects Analysis): is a 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 will be updated as the design changes and progresses through design verification and production. The first iteration should be done before Engineering part release as defined within each MAGNA STEYR Fahrzeugtechnik vehicle program. DOE (Design Of Experiments): is 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. DVP&R (Design Verification Plan & Report): is a 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. DV (Design Verification Testing): demonstrate that the final released component or assembly meets design intent. The tests, sample sizes, and performance requirements are detailed in Engineering Standards. 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.


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ERROR AND MISTAKE PROOFING: are defined separately. Error proofing is a method used to identify potential process errors and either design them out of the product or process, or eliminate the possibility that the error could produce a defect. Mistake proofing is an approach used to develop methods to clearly identify errors that may occur and prevent them from becoming non-conformances. FIRST TIER: is a term used for a Supplier who is responsible for providing components, services, or raw material directly to MAGNA STEYR Fahrzeugtechnik. FPSC (First Production Shipment Certification): the purpose of the FPSC program is to insure that the initial production shipments meet all MAGNA STEYR Fahrzeugtechnik drawing and Engineering Standards requirements. FPSC is intended to identify part problems and contain the parts at the Supplier during first production shipments to ensure a successful launch. The FPSC program requires the Supplier to provide statistical evidence of conformance to special product and/or process characteristics prior to the shipment of components to MAGNA STEYR Fahrzeugtechnik receiving plants. Certification is for a minimum of 1200 parts.100% of the FPSC parts are to be inspected for conformance to special product and/or process characteristics. FTC (First Time Capability): the purpose of the FTC is part of a process capability study that identifies the capability of a process (how well it produces quality parts) by operation. FTC can also be extended from just one (1) operation to the overall production process (Plant FTC). GAGE INSPECTION INSTRUCTIONS: are documented instructions for a specifically identified gage indicating step by step procedures for its use or layout of a part. HOME LINE: Supplier's assembly line located in the manufacturing facility where volume production of the part(s) takes place using production tooling and processes. IAA (Interim Approval Authorization = “Bauabweichung”): documentation and approval to temporarily use a part that does not meet PPAP approval requirements for Pilot builds or launch. ISO/TS 16949: is a Technical Specification that describes, in conjunction with ISO 9001 in it’s latest version, the Quality System Requirements for Automotive Suppliers. ISO/TS 16949 has been prepared by the International Automotive Task Force (IATF) for all participating worldwide OEM’s and may become the Quality Management Standard of the future. KEY CHARACTERISTICS: are features applicable to a component, material, manufacturing, or vehicle assembly operation which are designated by MAGNA STEYR Fahrzeugtechnik Engineering as being critical to part function, fit or appearance, and having particular quality, reliability, durability or functional significance. LIFE EXPECTANCY: is a time established service or operating life objective of a system, component, or material. LINE SPEED: is the contracted maximum tool capacity rate determined by dividing the Quoted MAGNA STEYR Fahrzeugtechnik Tooling Capacity (Pieces per Hour) by the Supplier's Quoted Net Operating Time for MAGNA STEYR Fahzeugtechnik Parts (Hours/Day). The Line Speed must be verified during the Production Demonstration Run while process performance studies are maintained at a level greater than or equal to 1.67 PPK. LOT: is not to exceed eight hours or one day’s production, whichever is smaller.


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MANUFACTURING FLOOR PLAN: is 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 should also indicate any proposed areas for expansion and development. 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. MSA (Measurement System Analysis, Repeatability and Reproducibility): is 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). NET OPERATING TIME FOR MAGNA STEYR Fahrzeugtechnik PARTS: is number of hours (normal work pattern), less scheduled “down-time” (breaks, start up, prev. maintenance, shared production, tool changes, shut down) and unscheduled “down-time” (estimated, based on historical or projected information). In case of multiple MAGNA STEYR Fahrzeugtechnik part numbers the changeover time has to be considered. OPERATOR INSTRUCTIONS: are lists of steps that may contain inspection requirements, required tools and gages, SPC applications, sample size and frequency, and acceptance/rejection criteria. They should communicate all requirements involved in the process. These must be readily available to the operator. PACKAGING: is 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 NUMBER and Part Change Level: usually is an eight digit number which represents a production part number followed by two alphanumerical digits for the change level which are assigned to a commodity or part. These numbers are assembled to describe the MAGNA STEYR Fahrzeugtechnik Engineering Bill of Materials used in building a vehicle. PERISHABLE TOOLS: are tools which are consumed in the process of producing a product, and are usually a cost item, i.e., drill bits, cutters, sockets, driver tips, inserts, hobs, broaches, welding tips, etc. POKE YOKE: is a method to improve Product Quality by preventing defects. PRE-PSO MEETING: is a meeting conducted by the PSO Team, chaired and coordinated by the Supplier Quality Specialist with the Supplier and their Advanced Quality Planning Project Team. The meeting is conducted at a MAGNA STEYR Fahrzeugtechnik selected location prior to the planned Process Sign-Off (PSO). The purpose is to review all of the Supplier's advanced quality planning and system plan documents in a sequential way and determine the Supplier's readiness to demonstrate a first Production Demonstration Run in the form of a PSO. PM (Preventive Maintenance): is a planned system of actions performed to prevent breakdown of a machine or equipment as a result of normal use.


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PST (Problem Solving Techniques): are methods used to identify the "root cause" of a problem. The most common forms of PST are corrective action teams, Quality Circles, Multi-Vari Charts & Analysis, Design Of Experiments (DOE), Benchmarking, Root Cause Analysis, Fishbone Diagramming, Quality Function Deployment (QFD) teams, Shainan Consultants Inc.'s, trademarked PST techniques (Isoplot, Red"X", Rank Order ANOVA, etc.), Pareto charts, & many more. The most successful techniques have employee teams contributing in some special way to perform "root cause analysis" and then permanently solve the issue or problem. PROCESS: is a combination of people, equipment, methods, materials and environment that produces a product or service. Any aspect of a business may be involved. PROCESS CAPABILITY: is the total range of inherent variation in a stable process. It is determined using data from control charts. The control charts shall indicate stability before capability calculations can be made. Histograms are to be used to examine the distribution pattern of individual values and verify a normal distribution. When analysis indicates a stable process and a normal distribution, the indices CP and CPK can be calculated. If analysis indicates a non-normal distribution, advanced statistical tools such as PPM (Parts Per Million) analysis will be required to determine capability. If control charts show the process to be non-stable, the PPK index can be calculated (see Fundamental Statistical Process Control reference manual). PFMEA (Process Failure Mode & Effects Analysis): is a structured method of documenting historical or potential process failure modes, their effects, and the controls taken to ensure their prevention. The PFMEA rating system allows quantification of the risk presented by each failure mode. The risk rating should be used to prioritize failure prevention. The PFMEA should be developed by a cross-functional team and should be uniquely developed for each process/product. PROCESS FLOW DIAGRAM/CHART: illustrates the flow of materials through the process. Usually starting at receiving, material in process, through shipping including any special processing which may result from a nonconformance requiring disposition, rework or repair operations. PROCESS PERFORMANCE AND PROCESS CAPABILITY INDICES (PP, PPK, CP and CPK): are defined in Statistical Process Control manual. PSO (Process Sign-Off) ON-SITE VISIT: is a systematic and sequential review of the Supplier's manufacturing process conducted by a PSO Team at the Supplier’s production facilities. Supplier Quality is responsible for team leadership. PRODUCTION DEMONSTRATION RUN: is a production run consisting of 300 or more parts (6 or more hours of production), from the production line of record, using trained operators, production approved piece parts or materials from production sub-suppliers, and run at a rate equal to the quoted maximum tooling capacity. All special characteristics must meet or exceed a process performance of PP and PPK ≥ 1.67. FTC must be calculated for each station and overall. A MAGNA STEYR Fahrzeugtechnik Team will be on the manufacturing floor during the demonstration to observe and verify the documented production system. Production Validation (PV) test parts are taken from this run to demonstrate that the production process has not degraded the design performance that was verified by Design Verification (DV) testing.


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PPAP (Produktion Part Approval Process): process for ensuring that production parts are manufactured at the production site using the production tooling, gaging, process, materials, operators, environment, and process settings, (e.g., feed, speed, cycle time, pressure, temperature). Parts for production part approval must be taken from a significant production run. MAGNA STEYR Fahrzeugtechnik requires that this run is a minimum of six (6) 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. PRODUCT SPECIFICATIONS: are the sum total of engineering drawing requirements including standards referenced on those drawings and within the contract. 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, Temporary Standards, Process Standards, Laboratory Standards, Reliability Standards, or Performance Standards. PVT (Production Validation Testing): are demonstration tests performed to validate design conformance of initial production parts manufactured with production tools and processes. ROOT CAUSE: is the assignable source of variation that affects all the individual values of the process output/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. SPECIAL CHARACTERISTICS: product and process characteristics designated by MAGNA STEYR Fahrzeugtechnik and the supplier, including governmental regulatory and safety characteristics as well as characteristics selected through knowledge of the product or process. STATISTICAL CONTROL: is the condition describing a process from which special causes of variation have been eliminated. Only common causes remain; i.e., 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. SOP (Start Of Production): the start of volume production and assembly of vehicles. SOP must result in quality vehicles that meet all customer requirements and corporate objectives. All regulatory requirements and approvals will have been obtained. Part Supplier and assembly plant facilities will be complete and ready for full volume production. SPS (Statistical Problem Solving): is the organized use of special problem solving tools (e.g. Fishbone Diagrams, Pareto Charts, ANOVA, etc.), to better understand problems, their causes and determine solutions. SPC (Statistical Process Control): is 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-TIER SUPPLIER: provider of production materials, or production or service parts, directly to a tier 1 Supplier to MAGNA STEYR Fahrzeugtechnik. Also included are providers of heat-treating, painting, plating or other finishing services.


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SUPPLIER READINESS EVALUATION RUN: the first documented build attempt by the Supplier following installation, setup, and tryout of the production equipment and tools. The Supplier, with the concurrence of the MAGNA STEYR Fahrzeugtechnik Supplier Quality Specialist, will determine the quantity of parts that are completed during this run, but 30 pieces is a typical build size. The purpose of this run 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 MAGNA STEYR Fahrzeugtechnik PSO Team will evaluate the analysis of this run when deciding whether to schedule the PSO On-Site Visit. SUPPLY CHAIN: includes all suppliers used in producing a given part; from tier one to the source of production materials. 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 Requirements (in Units of Production) per Shift WARRANT: 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.


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6 FREQUENTLY ASKED QUESTIONS: 1. Can Pre-PSO Meetings for documentation be held at the Supplier's local facilities?

It is recommended that Pre-PSO Meetings to review the documentation be held at a MAGNA STEYR Fahrzeugtechnik facility. However, Pre-PSO Meetings can be held at a Supplier's local facility if the PSO Team agrees.

2. Define the difference between Documentation and Process.

Documentation refers to the detailed drawings, plans, instructions, and records that are supplied to satisfy the 20 PSO Checklist elements. These documents describe the design and manufacturing plan needed to produce a component in production volumes. The PSO Team will review the documents to determine if they satisfy the PSO Checklist documentation requirements. Process is the implementation and verification of the design and manufacturing plan presented under the documentation requirements. The PSO Team will observe the process and verify the accuracy of the documentation.

3. Our company is not required to do PSO based on the low risk rating.

If a component is determined to have a low risk rating, then the Supplier must complete their own internal PSO and make their records available for review by MAGNA STEYR Fahrzeugtechnik.

4. Can or should we hold up PSO approval if the Supplier refuses to provide hard copy of

proprietary documents? PFMEA may be considered a proprietary document. No, a Supplier may refuse to provide a hard copy of proprietary documents, but the Supplier must either come to MAGNA STEYR Fahrzeugtechnik and review the documents or MAGNA STEYR Fahrzeugtechnik representatives must go to the Supplier's facility to review the documents.

5. What if the documentation is related to several elements of the PSO Checklist. Do we need

to include a copy of the document in each section or is once enough? Once is enough. Reference the location of the document in the remaining sections.

6. Are you aware of any situations where a Supplier has refused to give us a document?

PFMEA for example is proprietary. Yes, but arrangements should be made to review the document in the presence of the Supplier. MAGNA STEYR Fahrzeugtechnik will not retain copies.

7. 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 should notify the responsible Supplier Quality Specialist and Buyer to obtain approval for the change.

8. Is there a particular Checklist element that applies to the compliance report?

Element 18, EVIDENCE OF PRODUCT SPECIFICATIONS lists the compliance report requirements. The PSO Team will review the product. There must be some assurance that the product is within specifications, i.e. PP and PPK should be >=1.67.

9. 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/Follow-Up Sheet that the PSO Team verified the measurement.


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10. 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.

11. Can the team accept 1.33 ≤PPK ≤1.67 and add a comment to QPF?

Yes, a comment must be entered on the form if PPK is less than 1.67 and assurance must be given to MAGNA STEYR Fahrzeugtechnik that no non-conforming products will be released and shipped.

12. FTC - why and what is acceptable?

The purpose of FTC is to determine how capable a Supplier's process is for producing good parts. There are no minimum requirements for a Supplier, but the PSO Team will determine what is acceptable. 100% FTC is always the goal.

13. 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. MAGNA STEYR Fahrzeugtechnik 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

14. There is a semantic difference between "minimum requirement" and "goal". Minimum

value should be 1,67 is stated in one location, in another it says the goal is 1,67. The goal is to reach the minimum requirements of 1,67, however, the PSO Team has the discretion to accept a PP and PPK lower than 1,67, provided the Supplier has a recovery plan and can ensure no non-conforming product is shipped (100% capable sorting).

15. Does the PSO Team have the authority to provide exceptions i.e., lack of a product FMEA

is acceptable? The PSO Team may take exception to a checklist element, but all deviations must be documented and reviewed by appropriate management.

16. CAN PARTS USED FOR PV TESTING BE SELECTED FROM A NON-SUCCESSFUL PRODUCTION DEMONSTRATION RUN? In general, parts for PV testing must be selected from a successful Production Demonstration Run, however, there are exceptions. The PSO Team will review any deficiencies. A non-successful Demonstration Run can only be used for PV testing if the deficiencies are due to documentation discrepancies or appearance (non-functional) issues not involving finish durability. It's a requirement that parts used for PV tests must meet the production design release configuration. PV parts must come from a Demonstration Run that meets the following requirements: a. Meets the Process Performance (PP and PPK) requirements or if not, has performance values

and a recovery plan judged acceptable by the PSO Team.´ b. The Demonstration Run was conducted at the quoted rate. c. Approved piece parts and materials were used. d. Production processes and production tooling were used. e. Acceptable MSA results were obtained for production measuring tools.

IF THESE CONDITIONS ARE MET AND THE PSO TEAM AGREES, PARTS FROM A NOT SUCCESSFUL DEMONSTRATION RUN COULD BE USED FOR PV TESTING.

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