PCPAPart Number:
RESULT:
1BKQ52
Guidelines
Date:
11-Sep-08NA
87271096 Odm:
Project:
Sprayer - Hood Supplier Name:Supplier Code:
FIACBRASSupplier Plant:
Part Hood - Fuel Tank Description:PROCESS VERIFICATION (VP)
Mat'l Request: Availability:1 - DOCUMENTATION 2 - TOOLING /
EQUIPMENT 3 - PROCESS
SQE: R. Mximo (vx822)PRE-SERIES (PS) Mat'l Request:
Availability:5 - PRODUCT 4 - HUMAN RESOURCES QUALIFICATION / ONE
& ORGANIZATION DAY PRODUCTION
Sumar (SP)### ###
RELEASE TO PROD. (DaP) Mat'l Request: Availability:6 -
IMPLEMENTATION OF QUALITY 7 - IMPLEMENTATION OF QUALITY
CURRENT PRODUCTION Mat'l Request: Availability:8 - LOGISTIC 9 -
CONTINUOUS IMPROVEMENT
Drawings A F-C
Die status (quality, capacity and timing)
Tier 2 approval
Have operators been Self-Qualification status properly
trained?
Incoming Material Controls
Controls recording
Traceability
Lessons Learned
1Flow Chart
F-S
3
F
3
F
3Management involvement
F-S
2
F
3
F
4
F
4Identification
F
NV
B F
Equipment status (quality, capacity and timing) F-S
Tier 2 components approval
Integrative Tests Status
Production approval
Controls recording regarding Report Characteristics F
Improvement Activities for Tier 2 Suppliers
2
4
F
2
4Are the Resources dedicated to controls sufficient?
F-S-C
NV
F
3
1
4FIFO
F
NVWarranty
Process FMEA C F-S
Are clear operator Preservation conditions instructions
available of dies machines and and updated for each equipments
operation? F
Matchability and Benestare Status
Process Controls and Tests
Control instruments management
1
3s)
F
3
3If more than one shift, does information get passed across
shifts? F
F-S-C
NV
F
2
F
2Re-works
4Appropriate handling and packaging
F
4Periodic ReQualification
Process Control Plan (machines/dies/equipment D F-S
Ordinary and Preventive Maintenance
Process Capability (Ppk, Cpk & Cmk)
One Day Production
Outgoing Quality
1
F
3
F-S
NV
2
F-S
NV
F
2SQE Audit
F
4
F
3
NVQuality and Environmental certifications F
E
IMDS (Mgt. of use limitation Is the Special for dangerous or
Maintenance effective? forbidden substances)
Restart of production
Environment, Health and Safety (EHS)
Strengthened PreLaunch Control Plan
Non-conforming products management
Appropriate process flow
NA
F
3
F
3
2
NV
F-S
NV
3REMARKS & REMARKS & OBSERVATIONS OBSERVATIONS
F
3
4
na - Not Applicable nv - Not ValuatedSupplier Resp.: Name
1 - JOB STOPPER
4 - Planned 2 - JOB STOPPER 5 - Implemented 3 - 2nd Level Issue
Activity according Risk Activity to ProjectProgr. Mgr.Name Sign.
SQE: Name Sign.
ATTACHED DOCUMENT
Sign.
SQM: Name
Sign.
BACK TO PCPA FORM PCPA FORM AUDITOR REMARKS (SQE)
Positive Points:* Abertura e receptividade por parte da Empresa
e colaboradores; * Esforo em atender as solicitaes e necessidades
dos clientes; * Transparncia.
Improvement Points: * Necessidade de melhorias nas reas de
inspeo de produto acabado; * Necessidade de melhorias em sua
documentao tcnica: PFMEA, Fluxo de Processo, Planos de Controle; *
Necessidade de melhorias na gesto do Controle de Processo.
QUESTION
RANKING
OBSERVATION The supplier should be in possession of drawings
that reflect some form of customer approval; i.e. Design Engineers
signature, approved design change order, etc.
AUDIT EVIDENCES
CORRECTIVE ACTION
RESPONSIBLE
DATE6-Oct-08
STATUS
Rodrigo A.F. 1) O fornecedor no possuia cpia da norma
1/2)Solicitado cpia; DWGB105/09 (ou FIAT 01455/13) que determina 3)
Correo do desenho e envio a CNH Salgado (Suporte as tolerncias para
Synthetic Resin para aprovao (solicitao de CD) Tcnico Components;
Fiacbras)
J6-Oct-08
1A
1
2) O fornecedor no possuia cpia da norma The supplier should
demonstrate that the que estabalece o MS515 - Tupe III - Grade A,
technical documentation (Drawings, Technical que estabelece as
caractersticas fsicoSpecs., Standards and Norms) for the part,
qumicas da fibra-de-vidro; product or component under examination
shall be updated and available, whether the part 3) A pea fornecida
atualmente no is produced internally or purchased from representa
100% o desenho. Foram includos external sources. os insertos
FC-DI-537 (substitui o 311717), FC-DI-582-1, FC-DI-582-2 e
FC-DI-598 sem a devida aprovao da Eng. CNH; The drawings elaborated
by the supplier should show the adequate tolerances. The drawings
elaborated by the supplier should show the link between the
customers standards.
Rodrigo A.F. Salgado (Suporte Tcnico Fiacbras)
J06/11/2008Dependendo aprovao CNH do Eng. LUIZ GROPPO Dpto.
engenharia Piracicaba
Rodrigo A.F. Salgado (Suporte Tcnico Fiacbras)
K J K
1B 1C
2 1
The suppliers manufacturing facility should O fornecedor no
possui Fluxo de Processo have available a Process Flow Diagram.
formalizado. The supplier should have available an O fornecedor no
possui FMEAs de Processo acceptable PFMEA, witj acceptable RPNs,
formalizados. consistent with DFMEA, Process Flow and that includes
CNH important characteristics (CNH1 and CNH2).
- Concluir fluxo de processo; - Treinar Colaboradores; -
Implantar.
Atlio (CQ)
9-Oct-08
Sidelice (SGQ)/ 31/01/2009 - Agendamento de treianemnto FMEA
para a Finalizar at equipe; - Atlio (CQ) - 09/02/09 Elaborao e
implantao de Procedimentos; - realizao e implantao do FMEA.
Supplier Responsible_____________________ (Name and
signature)
SQE_____________________ (Name and signature)
1D
1
The supplier should have an available O fornecedor no possui
Planos de Controle Process Control Plan. formalizados. An
acceptable Process Control Plan should have: * numbers and controls
match PFMEA and Process Flow Chart; * includes CNH important
characteristics (CNH1 and CNH2); * recalls suitable frequencies and
sampling sizes; * include incoming, throughout the process to
labelling and shipping.
- Concluir planos de controle; - Revisar fluxograma de novo
produto FC.DC-15 incluindo plano de controle;
Atlio (CQ)/ Sidelice (SGQ)
9-Oct-08
J
1E 2A
NA 3
IMDS
IMDS no um requisito CNH.
NAAtlio (CQ) - Ao em andamento (revalidao dos gabaritos com
recuperao e tratamento de proteo superficial e gernciamento atravs
de planilha de controle e aprovao peridicas) 31-Dec-08
The supplier should manage the die status in O fornecedor deve
gerenciar a vida til de terms of (building and try-out) timing and
seus moldes e gabaritos, realizando functionality. manutenes
peridicas e try-outs dos mesmos. The supplier should manage the
environment where are stored the dies, with particular attention to
the conditions of humidity, protection, lubrication and
identification.
J06/10/2009 Finalizar 12/02/09
2C
3
O fornecedor no apresenta uma rea Com a concluso das instalaes
da ampliao Henrique destinada para o armazenamento de do prdio (em
andamento), ser construido um (Diretoria Comercial) / ferramentais
e gabaritos, ficando os mesmos galpo maior para melhor
armazenamento dos Claudio alocados na rea de produo. ferramentais e
gabaritos. (DiretoriaIndustrialI)
K J
The supplier should manage the preventive or O fornecedor deve
melhorar a gesto das predictive maintenance plan for all manutenes
preventivas das mquinas de production equipment directly connected
with spray-up, de modo a determinar frequncias the product
(including machine tooling). de manuteno, itens padro a serem
verificados e a gesto peas de reposio. The supplier should have
spare parts ready for those machines/tools that may cause stopping
of production. Estas manutenes devem ser registradas e
avaliadas.
2D
3
Devido a durabilidade muito variada dos componentes iinternos
das mquinas de SpryUp, manutenes preventivas peridicas completas se
tornam invivel para a Fiacbras, no entanto, realizado atualmente, a
limpeza, verificao e troca de componentes com probabilidade de
desgastes constantes, para isso temos um estoque mnimo desses
componentes, faltando no entanto um controle formal (registro da
manuteno); - Ser elaborado planilha de estoque mnimo de componentes
para reposio e implantao de planilha de controle das manutenes.
Sidelice (SGQ)/ 15-Nov-08 Manuel (Laminalo)
Sidelice (SGQ)/ 15-Nov-08 Manuel (Laminalo)
J
2E
3
The supplier should have a trained maintenance team (internal or
external) available for intervention also in case of emergency
during all working time. Special maintenance interventions must be
recorded.
As manutenes corretivas das mquinas de spray-up devem ser
registradas e avaliadas de modo a re-alimentar as manutenes
preventivas.
Idem 2D 3
JAtlio (CQ/ Sidelice (SGQ) 15/11/2008 Depende CNH (desenhos item
1A1-3)
3A
3
The supplier should have an approved Utilizao de
sub-fornecedores sem a devida - Realizar e implantar PPAP
(Denesfer); supplier list exist for all components aprovao
(DENESFER no homologado). - Rever sistemtica FC.PR-04 needed for
the assembled part (commodity or (Procedimento de aquisio)
technology) Adicionalmente, recomendada a reviso da OBS: Agendar
treinamento PAPP sistemtica de avaliao via IQF e IFF. para
suprimentos e qualidade para o 1 trimestre de 2009
K
Supplier Responsible_____________________ (Name and
signature)
SQE_____________________ (Name and signature)
3B
2
Atlio (CQ)/ The supplier should have a sitematic process No
foram encontradas evidncias de - Solicitao de anlise dimensional e
to qualify purchased product/material prior formalizao de anlise e
aprovao dos certificados de Qualidade ao fornecedor; - sidelice
(SGQ) to its being used in its production line. insertos FC-DI-537
(substitui o 311717), FC- Verificao e Aprovaao da analise pela The
management of modified DI-582-1, FC-DI-582-2 e FC-DI-598 quanto:
Fiacbras; material/components should be guaranteed. * Anlise
Dimensional; Envio para aprovao CNH e; * Certificados de Qualidade
de Matria- Formalizao do procedimento Prima; atravez da adio no
procedimento FC.PR-04 * Certificados de Qualidade do Acabamento
(Aquisio). Superficial.
15/11/2008 depende CNH (desenhos item 1A1-3)
K
3C
3
The supplier shoud provide in the A IT Aplicao de GEL COAT
(Rev03 workstations clear operator instructions and 03/10/07)
estabelece a necessidade de parameter set-up instructions according
to aplicao de 03 camadas de gel, entretanto the needs and method of
production. Such os operadores aplicam 02 camadas. documents shall
be easily identifiable for the various steps related to the usage
(e.g. classification, colours, pictures/sketches/drawings, etc.) to
avoid any possible mistake.
- Revisar FC.IT-010 mantendo especificado apenas a espessura
final do gel; - Providnciar medidor de espessura de gel e deixar no
posto de trabalho; - Orientar (treinar) operador;
Sidelice (SGQ)/ 15-Nov-08 Vincius (Compras)
J
Process Capability (Ppk, Cpk & Cmk)
NA No foi eveidenciada a existncia de uma sistemtica para a
realizao de estudos de capabilidade. O fornecedor deve avaliar a
viabilidade e exteno da realizao destes estudos. Vale a pena
destacar que os itens produzidos so confeccionados em
moldes/gabaritos o que, quando com processos controlados
adequadamente, pode ser considerado como uma inspeo 100%.
3D
NV
The supplier should have, according to requirements,
instructions concerning equipment management in case of production
changes or re-starts (set-up).
3E
3
1) Foi detectado peas em estgios avanados - Diminuir quantidade
de peas por Ordem de Natanael (PCP) de processo (laminao, rebarbao,
Produo para dinamizar o giro da mesma; acabamento) com a Ordem de
Produo na etapa - Auxiliar de de laminao, sem as aprovaes PCP,
contrada para a funo a um ms, est formalizadas; auxilido PCP para
agilizar a elaborao e emisso das OP's evitando assim a falta da 2)
A Ordem de Produo 2150 (03/09/08) mesma nos postos de trabalho.
solicita a confeco de 03 unidades. Na realizao da auditoria, j
haviam sido entregues para a CNH 02 unidades, entretando a OP ainda
estava incompleta. O fornecedor deve gerar o controle de OP
parciais.
9-Oct-08
J
Supplier Responsible_____________________ (Name and
signature)
SQE_____________________ (Name and signature)
The supplier should have a record of training courses completed,
as well as a skills matrix chart identifying the versatility of the
employees shall be available. This matrix shall be consistent with
the days of work and number of shifts per day.
4A
3
The responsibility for the management/updating of the
versatility matrix shall be defined.
O fornecedor possui uma Matriz de 1/2) Nova avaliao da matriz
observando as Sidelic (SGQ) Competecncias (2Sem/08), entretanto a
falhas citadas (incluso do auxiliar de mesma est desatualizada:
inspeo, incluso dos supervisores na 1) Foi detectado que um dos
colaboradores matriz de fabricao para suprir atividades designados
para a avaliao e liberao de onde no h colaborador aptos a treinar;
itens acabados no estava listado na matriz. 3) 2) Existem
atividades onde no existem Disponibilizar matrizes atualizadas nas
colaboradores aptos para o reas de trabalho;
treinamento/multiplicao; 4) Atualizar matriz com as competcias dos
3) As matrizes no esto disponibilizadas lideres/ supervisores. nas
reas de trabalho; 4) As matrizes no apresentam as competncias dos
lderes/supervisores das reas.
15-Nov-08
J
4C
3
The supplier should provide an adequate A rea destinada a inspeo
final dos itens - Est sendo providnciado iluminao number of
resources involved in the process, necessita de iluminao
diferenciada apropriada para rea de inspeo; ensuring the coverage
of all working shifts. (avaliao de cor) e que no seja contaminada
pela poeira proveniente do processo de acabamento. Adicionalmente,
recomendada a instalao de uma cabine de luz para avaliao de padres
de cor. The supplier should have an effective communication,
particularly across shifts, dept's., etc., that problems info
quickly reach the correct personnel. O fornecedor no possui
formalizada a transmisso de informaes entre turnos Em fase de teste
planilha de comunicao entre os turnos; semndo aprovada, a mesma ser
implantada e inclusa no procedimento FC.DC-06 (Controle de
Produo).
Claudio/ Henrique (Diretoria)
6-Dec-08
JNatanael (PCP)/ 31-Oct-08 Sidelice (SGQ)
4D
2
J6-Dec-08
4E
2
Claudio/ The supplier should demonstrate a cleaning Em virtude
das caractersitcas do processo Baseado em 18 anos de experiencia na
plan of workplaces in order to maintain the atual, seu do fluxo
fsico e instalaes, as fabricao de produtos com fibra de vidro,
Henrique (Diretoria) right level according to product reas de
produo apresentam um grande sem nunca ter constatado contaminao que
criticality. There shall be taken in account potencial de
contaminao durante as fases: comprometesse a qualidade do laminado
ou on working cycles a time dedicated to clean * Laminao; perda de
processo, a Fiacbras no v the workstation. * Aplicao de Gel-Coat e
Pintura; necessidade de mudanas nesse aspecto; no * Inspeo Final.
entanto, a Empresa se encontra em fase de ampliao (construo), o que
pode ter Adicionalmente, as reas de laminao causado algum impacto
negativo durante a possuem pisos revestidos de areia, o que
auditoria. pode vir a contaminar as mantas/resina Com a concluso
das instaes e mudana do durante a laminao (ver 6C). processo de
laminao para o novo galpo, esses processos vo ficar livres do p,
que possa estar vindo do setor de acabamento.
J
Self-Qualification status
5A
2
O fornecedor no avaliou os seguintes - Reviso dos desenhos;
tpicos durante o desenvolvimento do item: - Solicitao do CD a CNH.
* Cotas de simetria 518 mm e 583 mm no foram medidas; * O molde
desenvolvido no foi elaborado com base no modelo 3D e sim em
amostra; * No apresentou o dimensional dos insertos.
Rodrigo A.F. Salgado (Suporte Tcnico Fiacbras)
06/11/2008Dependendo aprovao CNH do Eng. LUIZ GROPPO Dpto.
engenharia Piracicaba
K
Supplier Responsible_____________________ (Name and
signature)
SQE_____________________ (Name and signature)
5C 5D 5E 6A
NV NV NV 3
Matchability and Benestare Status One Day Production
Strengthened Pre-Launch Control Plan The supplier and the
sub-suppliers should have a procedure to manage purchased
material/raw material with significant characteristics assigned,
including the recording and filing of inspection results.
Item de produo corrente em alterao de reviso de desenho. Item de
produo corrente em alterao de reviso de desenho. Item de produo
corrente em alterao de reviso de desenho. Foi detectado durante a
auditoria a utilizao de resina isoftlica no liberada. Resina ARAZYN
AZ110#00, lote 4333#00, NF 28729. "- Treinar e alertar
Colaboradores quanto as Elias (Logistica)/ identificaes de liberao
para uso; Sidelice (SGQ) Colocar placa de alerta sobre o lote a ser
liberado "NO APANHAR; AGUARDAR LIBERAO"31-Oct-08
J J6-Dec-08
6B
3
Ver observaes do tpico 3E. The supplier should have defined and
implemented controls on the first part produced in case of re-start
of production, after any modification, or change of manufacturing
process. The supplier should have process and machine 1) O processo
de laminao no assegura o parameters defined according to how is
controle de contaminao das camadas de prescribed into specs, norms,
drawings both manta/resina aplicadas. Durante a auditoria customer
and supplier (temperature, foi evidenciado que pedaos de manta que
pressure, voltage, current, load, capacity, caiam no cho de areia
eram colocados torque, etc.)? diretamente na pea em laminao;
Idem 3E
6C
2
1) Idem a 4E 2; Os Colaboradores do setor de Cleide / Manuel
(laminao) laminao sero orientados a ter mais cuidado no manuseio do
material. 2) Aquisio de 3 caixas de madeira (pint-las por dentro
com tinta preta)para armazenagem dos padres de cores SGQ, Pintura e
embalagem. 2) A gesto dos padres de cor deve ser 3)Os gabaritos
esto sendo revalidados melhorada. Foi detectado durante a auditoria
(conforme item 2 A3)e paralelamente, os Vincius The supplier should
demonstrated that the O (Compras)/ Jos method of recording data are
be verify as a guarda de padres na rea de pintura sem o projetos
sero formalizados. ou Leomir item descrito no item 3 ser
formalizado suitable for the checks being performed and devido
cuidado de preservao. conforme o prazo de ao, os demais seguiro
(Produo) any control limits utilized should be 3) No foram
evidenciados projetos formais paralelo ao prazo do item 2 A3.
reasonable. dos gabaritos de montagem (adeso de Rodrigo A.F. 4)Em
Out of control conditions or special causes insertos) do item
87271096, o que vem Salgado of variation should be clearly
identified, dificultar o controle/manuteno dos mesmos. anlise a
viabilidade do estudo e das (Suporte necessidades (treinamentos,
planilhas, etc.) Tcnico documented and linked to a robust
corrective 4) O fornecedor dever confeccionar um Fiacbras) action
support system that is responsive to quadro com os principais
defeitos the operator. encontrados em seu processo de pintura
(Arranhes, gotejamento, casca de laranja) de modo a servir de apoio
a seu pessoal de inspeo. Atlio (CQ)/ The supplier should use a
system for the sidelice (SGQ) easy identification of conforming
products already produced (lot breaker, control charts, etc).
J15-Nov-08
J06/11/2008Dependendo aprovao CNH do Eng. LUIZ GROPPO Dpto.
engenharia Piracicaba
K
15-Jan-09
J15/01/2009 finalizar 09/02/09
6D 6E
2 NV
The supplier should have and apply an adequate Product Audit
Plan: * Results of previous audits shall be available; * Reaction
plan if defective parts are discovered shall be available. SQE
Audit
No foi evidenciada a realizao de auditorias sistemticas de
produtos e processos.
Ser feito planejamento para realizao de Atlio (CQ) auditorias de
produtos com incio a apartir de jan/09.
K
Tpico no avaliado durante a realizao da auditoria.
Supplier Responsible_____________________ (Name and
signature)
SQE_____________________ (Name and signature)
7B
1
The supplier should provide, perform and No foram evidenciados
os registros de record controls directly to the product for
processo referentes ao controle/avaliao parts with Saferty/Report
Characteristics das caractersticas CNH1 ([>). and/or subject to
homologation, in order to ascertain conformity of the related
characteristics.
- Identificar processos crticos atravs do Sidelice (SGQ)/
15-Nov-08 Atlio (CQ ) desenho; - Incluir na Ficha de Processo de
realizao do produto.
J
The supplier should have available Master Parts to confirm
inspection and error proofing devices.
1) Idem ao item 6C. 1) A gesto dos padres de cor deve ser
melhorada. Foi detectado durante a auditoria a guarda de padres na
rea de pintura sem o devido cuidado de preservao.
Jem andamento finalizar at 09/02/09
7C
2
2) Para inspees visuais, como cor e acabamento, o fornecedor
deve realizar The supplier should have a gauge calibration estudos
de R&R de modo a verificar a system, including calibration
frequency and confiabilidade de suas avaliaes. recording of
relevant results.
KAtlio (CQ) Vincius (Compras)/ 15-Nov-08
7E
3
The supplier should identify (via signs/documents, well
delimited areas, better if enclosed or adequate containers)
Non-conforming parts.
O fornecedor deve aprimorar a identificao Cercar rea de Segregao
de Produtos No de peas suspeitas e/ou no-conformes. A Conformes com
corrente. utilizao de reas/barreiras fsicas em adio a utilizao de
cartes de identificao deve ser considerada. O fornecedor deve
acionar a logsica CNH - Solcitao de analise de viabilidade de para
a anlise de viabilidade da utilizao aprovao de racks retornvis
junto a de embalagens/racks retornveis. CNH;F50 - Aguardando
aprovao CNH. As caixas de papelo utilizadas atualmente no asseguram
a integridade do item durante o transporte.
J06/11/2008 depende fornecimento CNH
The supplier should identify the packaging according to
standards agreed with the customer (packaging specifications).
Sidelice (SGQ)
8D
3
K6-Dec-08
The supplier should have the technical documentation to be used
in the workstations. This documentation should be easily accessible
without disrupting the working activity.
8E
2
recomendado que o fornecedor re-avalie o Considerando a fase de
ampliao da empresa Henrique (Diretoria fluxo de processo atual e
suas isntalaes e o fato de muitos processos serem Comercial) /
fsicas de forma a assegurar a qualidade dos provisrios, no momento,
a nica ao Claudio itens fornecidos. O controle de contaminao
possvel orientar os colaboradores quanto (Diretoria IndustrialI)
(por poeira/areia), durante o processo de a cuidados de manuseio.
Aps trmino da laminao e pintura deve ser garantido. ampliao, o
prprio layout com as novas disposies dos processos, permitir extio
Estes cuidados devem ser considerados no do p nos setores de
laminao e pintura de somente nas instalaes futuras (em gel.
construo) como nas instalaes atuais.
J
9A 9B 9D
NV NV NV
Lessons Learned
Tpico no avaliado durante a realizao da auditoria.
Improvement Activities for Tier 2 Suppliers Tpico no avaliado
durante a realizao da auditoria. Periodic Re-Qualification Tpico no
avaliado durante a realizao da auditoria.
Supplier Responsible_____________________ (Name and
signature)
SQE_____________________ (Name and signature)
BACK TO PCPA FORM
Contact ListAttendees [Y/N]
NAMEHenrique Ferraz Cludio Ferraz Atlio Sidelice Mata
COMPANYFIACBRAS FIACBRAS FIACBRAS FIACBRAS
DEPARTMENTGerncia Produo Qualidade SGQ
TELEPHONE NUMBER019 3803-1301 019 3803-1306 019 3803-1307 019
3803-1305
FAX NUMBER
E-MAIL
Y Y Y Y
019 3803-1309 [email protected] 019 3803-1309
[email protected] 019 3803-1309
[email protected] 019 3803-1309
[email protected]
PCPA GUIDELINES
1 DOCUMENTATION 1A Drawings Supplier must be in possession of
drawings that reflect the change level of the part being produced.
The drawings must reflect some form of customer approval; i.e.
Design Engineers signature, approved design Supplier must be able
to show that the customer approved drawing agrees with the part
being shipped.
The technical documentation (Drawings, Technical Specs.,
Standards and Norms) for the part, product or com and available,
whether the part is produced internally or purchased from external
sources.
The correct management of documents shall be shown. The auditor
shall verify the existence of a list with all are updated to avoid
the retention and use of obsolete drawings.
Tolerances must be shown on the drawing. The link between the
customers standards shall be shown; e.g. through a tree chart.
Geometric Dimensioning and Tolerancing (GD&T) must relate back
to data. Key Product Characteristics (KPC's) must be identified for
characteristics that are critical to variation in the pa on the car
(Note: it is not necessary that all parts have KPC's; the customers
product engineering group is resp KPC's).
If the technical documentation supplied by the customer does not
indicate the existence of significant characte minimum the supplier
should select characteristics that affect close tolerances, fit,
function, finish, reliabil process parameters and/or
characteristics that affect the successive/final process.
1B Flow Chart
The Process Flow Diagram must be available at the suppliers
manufacturing facility. The Process Flow Diagram must begin at the
material receiving area and continue through the entire proces and
Product storage areas. Any rework or repair operations must be
shown on the Diagram and indicate the flow of material back into
the repaired or reworked material back to the normal process where
production test equipments must re-check and
Gauging and Inspection areas must be shown in the process,
whether they are on the production line or off-l result in
scrapping the parts, this should be identified on the chart.
1C Process FMEA
Is there a PFMEA available and is it acceptable? Are RPNs
acceptable, is it consistent with DFMEA, n KPC's/PQC's/KCC's? Any
evidence that it is a living document?
PCPA GUIDELINES
Corrective actions to product/process shall be used to update
FMEA's and Control Plans. Since many product failures can be the
result of problems in the manufacturing process, the supplier must
use developing the PFMEA (e.g. PFMEA severity related to DFMEA
severity).
The supplier must be able to describe how critical design
characteristics that impact part performance were con
Process/Product FMEA shall be available for review by the
customer. Verify that the Process FMEA was generated by a
cross-functional team and follows the elements of the Pr occurrence
and detection appearing consistent with available quality
performance data.
Activities on RPN reduction should be visible and following an
ongoing process. A preliminary analysis on the manufacturing,
activities and controls means has to be conducted (using ass
knowledge of successive processes, knowledge of how the product is
used, etc.). At a minimum the supplie close tolerances, fit,
function, finish, reliability, durability, and/or are affected by
process parameters and/or ch process.
For Family PFMEA you need to have a periodic reviewed document
that shows evidence of PFMEA evaluation
All the activities that cause a cost increase for non-quality
(rejects, reworks, additional controls, etc.) shall be m
Actions aimed to restore initial/optimal conditions shall be
planned/implemented and there shall be evident the e
1D Process Control Plan
Is there a Process Control Plan (PCP) available? Is it
acceptable (numbers and controls match PFMEA and Process Flow
Chart, includes KPC's/PQC's/KCC's sizes, includes latest EWO/ODM)?
Did the supplier use the right mechanics to create the PCP (ref.
Fiat Standard 9.01102 and ISO TS 16949)?
PCP must include incoming, throughout the process to labelling
and shipping. During the launch period there shall be an Early
Production PCP (strengthened Plan). There shall be an organized
structure to guarantee the updating of the control
methods/conditions with the evol Any significant characteristic
shall be designated by appropriate symbols throughout the whole
documentation.
The classification of product characteristics shall be indicated
on each Control Plan or Operating Instruction specifications and/or
preventive analysis performed on the product when requested (FMEA,
DOE, etc.).
The management on PCP of Safety/Report Characteristics and/or
Homologation Characteristics shall comply w
Control plans and/or Inspection Instructions, compliant with
updated drawings, safety and significant character purchased parts.
Documentation used to conduct inspections (cycles, drawings,
instructions, etc.) shall be available at each work Review the
CONTENT of the PCP.
PCPA GUIDELINES
The adequacy of the contents of PCP or written instructions
(characteristic, control frequency, sample size, me etc.) shall be
ensured. For Family PFMEA you need to have a periodic reviewed
document that shows evidence of PCP review for pot Ensure that the
Process FMEA was utilized in compilation of the PCP with emphasis
placed on KCC's / KPC's.
Seek evidence that control plan is a living document subject to
regular review. Process/machine parameters subject to significant
alterations over time (e.g. temperatures, times, speed monitored,
automatically or manually, with respect to set tolerances.
Check the evidence of controls related to highest RPN's. The
control frequencies, size and methodological criteria shall be
defined. It is necessary to take into acc functionality of the
product as defined by preliminary analysis (e.g. FMEA) and the
stability of the process gene
1E IMDS (Management of use limitation for dangerous or forbidden
substances)
Supplier shall have the reference set of rules where are written
the use limitation (Fiat Cap. 9.01102 Fiat Ca recalled in those set
of rules. Supplier must have sent the use limitation to its
Suppliers. Supplier must have asked its Suppliers for the involved
applications and must retain copy of the documentation
Supplier shall have copy of the documentation requested by Fiat
Auto. Supplier shall have answered the requests of Fiat Auto in the
expected time and shall retain copy of the sent do If specific
materials/components need adjustment due to a substance
elimination, Supplier shall carry out compliance with obligations
and shall manage the traceability of components before and after
modification.
Supplier shall quickly communicate to Fiat Auto the adjustment
in progress through the sending of updated involved Part Numbers.
Does Supplier insetred all data related to Fiat PN's of its own
supplying into IMDS (International Material Data S
Supplier shall have the reference set of rules specific for IMDS
(Fiat Cap. 9.01107). Supplier must be registered to site
www.mdsystem.com. Supplier shall be aware of the presence of an
Help Desk and a reference person in Fiat Auto as an help for
the
Supplier shall have involved its own suppliers for the insertion
of their data and shall retain the related documen Supplier shall
be structured in order to guarantee the MDS insertion for all Fiat
PN's within the Benestare control for those arrived by tier 2
Suppliers. Supplier shall update the MDS every time a significant
variation of total weight of the product (>10%) occurs or (also
regarding surface treatments) through an automatic change of
modification level into the IMDS.
Supplier is responsible of all data inserted in its own MDS,
also those related to materials/components of Tier 2
PCPA GUIDELINES
2 TOOLING / EQUIPMENT 2A Die status (quality, capacity and
timing) The auditor shall verify die status in terms of (building
and try-out) timing and functionality. The auditor shall verify the
number of cavities and the consistency of life time with the
estimated needs. The auditor shall verify the implementation of all
requirements contained into the tooling sign off. 2B Equipment
status (quality, capacity and timing) The auditor shall verify
tooling status in terms of (building) timing and functionality. The
auditor shall verify the presence of all necessary equipments to
make definitive the process. 2C Preservation conditions of dies
machines and equipments
The auditor shall verify the environment where are stored the
dies, with particular attention to the conditi identification. Do
the conditions guarantee the functionality through time? 2D
Ordinary and Preventive Maintenance (machines/dies/equipments)
There shall be a programmed, preventive or predictive
maintenance plan for all production equipment dire machine
tooling). This plan shall be complied with, and all interventions
performed shall be recorded in a logbook (ordina included). The
records shall be analyzed to identify any weakness in the equipment
and/or in the maintenance plan. There shall be spare parts ready
for those machines/tools that may cause stopping of production.
Customer owned tooling, gauges, etc., must be permanently
identified and included in the maintenance plan.
2E Is the Special Maintenance effective?
There shall be a trained maintenance team, internal or external,
available for intervention also in case of emerg Special
maintenance interventions must be recorded.
3 PROCESS 3A Tier 2 approval Does an approved supplier list
exist for all components needed for the assembled part?
PCPA GUIDELINES
Is there a list of qualified suppliers for each commodity or
technology? Are there been any changes on the supplier list agreed
during the APQP or the Part Approval? There shall be a
systematically updated list indicating one or more qualified
suppliers for each specific drawing,
There should be some methods to assess the adequacy of Tier 2
supplier performances. For critical supplier there should be a
flexibility to switch production between PPAP approved/benestariati
supp
3B Tier 2 components approval
How does the supplier qualify purchased product/material prior
to its being used for the product being aud completion and validity
of the controls performed or certified; if obtained from multiple
moulds, dies, or multi-c mould, die, cavity).
Is the management of modified material/components guaranteed?
Before starting production, the sub-supplier shall receive part
approval on samples submitted to the supplie production tooling
under normal production conditions. Part approval must ensure that
the samples produce drawing, technical specifications, and are
compatible with the customers processes and use on the final pro
moulds, dies or multi-cavity equipment, each mould/die/cavity shall
be identified in a permanent way on the pa each of them, in order
to carry out separate dimensional controls.
The separate sampling is also required for parts of the same
size but different characteristics (colour, hardness
If the approval is granted via deviation, this shall be
temporary and shall indicate the quantity and/or the valid tim
Deviation on characteristics that may affect the fit or
functionality of the component shall be authorized in writin When
applicable, the auditor shall verify the existence of any master
samples. The auditor shall verify the conformity of the part to the
technical specifications. 3C Are clear operator instructions
available and updated for each operation?
Workstations shall be provided with clear operator instructions
and parameter set-up instructions according to the planning and
development of these instructions, special attention should be
given to operations where in easily identifiable for the various
steps related to the usage (e.g. classification, colours,
pictures/sketches/drawi
The auditor shall verify the knowledge and the application of
procedures and job instructions by the operators. The auditor walk
the line having the CP and cross-checking the control instructions.
Review the adequacy of Visual Controls. 3D Process Capability (Ppk,
Cpk & Cmk)
PCPA GUIDELINES
For all important measurable characteristics the process
capability indexes must be calculated: Cm and Cmk Cpk for ongoing
process capability. It is necessary to consider the process
specific characteristics (e.g. presen characteristics under
examination (e.g. unilateral, bilateral limits) when defining the
statistical model to be used
Acceptable values shall meet customer requests for Cm, Cmk, Cp,
Cpk, short and long term (ref. Fiat Norm 9.0
If the process should result not capable, 100% product
inspection must be performed. Additionally, the proces a more
capable process must be developed.
Capability must be determined under the normal production
conditions (e.g. machine or equipment installed in t
Process capability must be monitored over time to guarantee its
ongoing stability. This must be done using ade at fixed intervals
by the same initial method.
Machine capability must be re-calculated when there are any
modifications to the product or process, major m the machine is
moved. All the above data, as well as any corrective actions
implemented as a result of the elimination of special ca relevant
forms. In the event the results of process capability are less than
the objective, it shall be provided for: - reviewing periodic data
processing and re-calculating control limits; - reviewing sampling
frequencies; - increasing inspections accordingly; - availability
and traceability of actions recorded in a logbook; - determination
of the effectiveness of actions. When the type of process utilized
does not permit to operate at the objective/required capability, it
is useless t be replaced with a more robust 100% control. Reference
documentation shall be updated accordingly. The auditor shall
request all values of Ppk, Cpk and Cmk and shall verify if they
meets specifications. If it is ne the data directly taken from the
process.
3E Restart of production
There shall also be, according to requirements, instructions
concerning equipment management in case of prod
Whenever necessary parameter values shall be recorded at the
start of production; these should be analyzed t
4 HUMAN RESOURCES & ORGANIZATION 4A Have operators been
properly trained?
PCPA GUIDELINES
Personnel shall be qualified to carry out the assigned tasks
(use of equipment, compliance with work instruc and identification,
consequences of non-conformities to product and the company caused
by activities not pro and/or machine failures) and the
management/setting of new equipment/machines.
Further qualifications shall take place after training. Training
plans shall be commensurate to the importance of the
characteristics controlled. The personnel shall be trained on the
product, critical points in general and in particular on the
difficulties whic (particular attention to be given to
Safety/Report characteristics). A record of training courses
completed, a versatility of the employees shall be available. This
matrix shall be consistent with the days of work and numbe
A periodic updating of training plan shall be defined. The
responsibility for the management/updating of the versatility
matrix shall be defined. The auditor shall verify the effective
distribution of training courses to operators. 4B Management
involvement Is Management involved in quality issues? Are Action
Plans made within the timing shared with the customer? Is
responsibility for implementation assigned and do people understand
their responsibility? 4C Are the Resources dedicated to controls
sufficient? Is the number of resources involved in the process
adequate? Is coverage of all working shifts guaranteed? 4D If more
than one shift, does information get passed across shifts?
Seek evidence that effective well defined lines of communication
are in place, particularly across shifts, dept's correct personnel.
4E Environment, Health and Safety (EHS)
There shall be a cleannes plan of workplaces in order to
maintain the right level according to product criticity. cycles a
time dedicated to clean the workstation.
Supplier shall demonstrate - where it is applicable - to have
either the Fire Prevention License or, for plants out Is the
Supplier certified or have a planning to meet ISO 14001
certification?
5 PRODUCT QUALIFICATION / ONE DAY PRODUCTION 5A
Self-Qualification status
PCPA GUIDELINES
Has been the Self-Qualification procedure completed? Are the
test results positive? Has been the test reports shared with the
customer? If not, are clear the recovery actions related to the
underlined anomaly? 5B Integrative Tests Status Has been the
samples for integrative tests delivered? Are the test results
positive? If not, are clear the recovery actions related to the
underlined anomaly? 5C Matchability and Benestare Status Has been
the samples for matchability and Benestare tests delivered? Are the
test results positive? If not, are clear the recovery actions
related to the underlined anomaly? 5D One Day Production
Has been the productive capacity process verified? Is the
productive capacity sufficient to meet the customer requests? Does
the verified productive capacity include the amount for spare parts
and possible production increases req of time? 5E Strengthened
Pre-Launch Control Plan
The auditor shall verify the existence of the Strengthened
Pre-Launch Control Plan, characterized by the pres frequencies
and/or sampling sizes higher than usual and by the presence of a
final control station off line for the
This station shall be in adequate conditions for the right
functioning (lighted place, necessary equipment availab
The auditor shall verify the adequacy of the Strengthened
Pre-Launch Control Plan, for example checking correspond more
severe controls or checking if all most important characteristics
(Key, Critical, ...) have been ta
The auditor shall verify that the responsible for execution of
the Plan have been identified and he correctly certi
6 IMPLEMENTATION OF QUALITY 6A Incoming Material Controls
PCPA GUIDELINES
For purchased material/raw material with significant
characteristics assigned, what is the sub-suppliers processes (i.e.
control plan), including the recording and filing of inspection
results? When it is necessary effective controls, using an adequate
sampling plan, shall be exercised both in the Incoming Inspection
are prevent/block the use of non-conforming parts or raw
material.
The control plan used shall be available and the related results
of inspections and tests shall be accessible on r
The methodologies for retaining the performed/certified quality
checks shall be defined. All components must be approved with
customer requirements. When applicable, it must be verified the
existence of deposited reference samples. If there is a
computerized system to manage incoming products, sampling plans and
acceptance/reject crit method in case the system were not
operational.
Control plans shall be developed and used (characteristics,
frequencies, sample sizes), assuring the approp characteristics, in
order to allow periodic re-examination, data processing and
acceptance criteria evolution.
Sub-suppliers may operate in self-certification status if they
at least have quality system certification requirem quality
performances suitable to the importance/product quality goals.
Procedures shall be defined for suspension/re-establishment of
the self-certification status when non-conformit Results of
inspections and tests shall always be available and promptly sent
to the customer if required.
A specific symbol showing the self-certification status shall
appear on the material shipping documents, produc
Audits on incoming lots shall be done randomly and statistical
evaluation of the results shall be made in ord indicators. A
structure able to intervene on the sub-supplier shall be operating,
in terms of: - process auditing for each new product/process; -
analysis and sharing of control plans in case a product is new
and/or has been modified. There shall be adequate procedures for
the management of any modification concerning the product, proces
shall be shown through a correct management of product/component
modifications. Any product produced before a modification shall be
considered as non-conforming unless otherwise provided
6B Production approval
Controls on the first part produced shall be defined and
implemented in case of re-start of production, after a process.
Conformity to specification shall be guaranteed through: - part
approval by appointed personnel with specific approval
instructions. The instructions shall be available, co
- OK to produce given by suitable responsible after verification
of conformity to specifications of the first parts re -
availability of the related documentation concerning parts (charts,
instructions, etc.);
PCPA GUIDELINES
- availability of production tools, control and handling
equipment; - when applicable, availability at working station of
approved master sample part. 6C Process Controls and Tests The
supplier shall have a procedure for the detection and immediate
action on the process, when process drift
Have been process and machine parameters defined according to
how is prescribed into specs, norm (temperature, pressure, voltage,
current, load, capacity, torque, etc.)?
Check that process control limits are not confused with
tolerances. Control limits have to show continuous improvement
process in place. The method of recording data should be verified
as suitable for the checks being performed and any control control
conditions or special causes of variation should be clearly
identified, documented and linked to a rob responsive to the
operator.
The supplier shall use a system for the easy identification of
conforming products already produced (lot breaker
The supplier shall have procedure to inspect parts back to the
last in-control point/part, when a non-conformity There shall be
defined and applied rules for the management of major
non-conformities including: - identification of the non-conformity;
- root cause analyses; - interim and long term corrective actions;
- verification of effectiveness; - extension of improvements to
similar processes. Corrective actions to the process shall be used
to update FMEA's and control plans. The auditor shall verify at
least the management of a corrective action subsequent to a
non-conformity.
6D Outgoing Quality There shall exist and be applied an adequate
Product Audit Plan: - results of previous audits shall be
available; - reaction plan if defective parts are discovered shall
be available. 6E SQE Audit In the Incoming Material Area select a
sample from previously accepted/approved lots and inspect it.
In the Manufacture Area, the auditor shall require parts to be
selected from different machines and different inspections,
checking the consistency of the results with the previous recorded
inspections, and comparing conformity, the results shall be
investigated to determine the root cause. The auditor shall verify
that the raw material being used is the same as approved by the
customer.
PCPA GUIDELINES
During the examination of the complete sequence of operations,
audits/inspections shall be performed by the a selected from a
minimum of three machines/processes and audit them relevant to
selected characteristics.
At the auditors option, check 15 pieces from each of the three
machine/processes to demonstrate process con
In the Shipping Area select samples from previously
accepted/approved lots that are ready to be shipped
characteristics. During the Product Audit, did the inspection
personnel show to be adequately trained? Are the inspection methods
performed in a way that is consistent and adequate with the
inspection requiremen Are the results of the audit conforming?
7 IMPLEMENTATION OF QUALITY 7A Controls recording Conditions and
responsibilities shall be defined for the recording and filing of
inspection and test results. Procedures for storing the documents
in suitable places shall be defined and applied. 7B Controls
recording regarding Report/Safety Characteristics
For parts with Saferty/Report Characteristics and/or subject to
homologation, controls directly to the product sh order to
ascertain conformity of the related characteristics. These controls
joins those normally provided on pr of these characteristics and
that shall be recorded as per the Fiat Standard 9.01120 "Report
Characteristics".
The formalization of these controls shall be on the PCP, both on
the step in which the characteristic is generate annex thar resume
these controls. This document shall be handed to the SQE. In this
formalization shall also be made clear controls performed on
characteristics realized at Tier 2 plants.
7C Control instruments management
There shall be a sufficient quantity of inspection and test
equipment to carry out the necessary controls (person Are boundary
samples available to operators and in use? Do all gauges have
operator instructions attached and clearly visible? Are Master
Parts available to confirm inspection and error proofing devices?
Gauges and measure equipment shall be of adequate measuring class
commensurate to the requirements of characteristics.
PCPA GUIDELINES
Availability, suitability, identification, efficiency, correct
storage of gauges, test equipment and reference sample
The supplier shall have a written, and properly applied,
procedure to audit the capability of the gauges for: stability. The
consistency between capability of the gauges and tolerances shall
be audited. There shall be a gauge calibration system, including
calibration frequency and recording of relevant results.
Gauge identification, calibration status and expiration date
(via calibration stickers, colour code, etc.) shall be e
The criteria adopted to guarantee the continuance of required
inspections and tests during the gauge calibrat the instrument is
sent to external laboratories).
There shall be gauge history cards containing start-up date,
interventions of calibration, as found condition, ma
There shall be gauge blocks and/or reference samples for gauge
calibration; traceable to the national standard
The appropriateness of the accuracy level of gauge blocks and/or
samples required for a correct calibration samples, etc.). Reaction
rules shall be defined in the event that any gauge is found out of
calibration. Identification and segregation of any non-conforming,
not capable gauge shall be ensured. Referability, metrological
traceability and calibration expiration date shall be shown. A
boundary sample and acceptance standards shall be available and
used for inspection of parts having appea shall be developed by
either the customer or the supplier.
The boundary sample shall be, when applicable, in each
inspection/control station. The identification and recording of the
modifications on the boundary samples shall be recorded on specific
cha
There shall be evidence of referability and traceability of the
master samples. Storage, handling conditions and preservation of
the boundary samples shall be defined. There shall also be,
according to requirements, instructions concerning gauge management
in case of producti
Gauges shall be provided with clear operator instructions, and
parameter set-up instructions according to the n planning and
development of these instructions, special attention should be
given to operations where inspec identifiable for the various steps
related to the usage (classification, colours,
pictures/sketches/drawings, etc.) t
The master sample shall be, when applicable, in each
inspection/control station. The identification and recording of the
intervention actions shall be recorded on specific charts. There
shall be evidence of referability and traceability of the master
samples. Storage, handling conditions, and preservation of the
master samples shall be defined. The auditor shall verify the
effectiveness of mistake proofing by simulating one or more
non-conformities.
Reference samples used to verify the operating condition of
gauges and inspection/test equipment shall be ava Reference samples
shall be used according to the frequencies set out in the Control
Plans.
PCPA GUIDELINES
Error proof (objective) 100% control requires that the detection
and rejection of parts are performed in an a down, or goes out of
calibration, the parts shall be selected as "non-conforming"
(positivity ofconsensus).
7D Re-works
Written instructions shall be developed for reworking, repair or
touch-up of non-conforming parts. The instruct equipment, the
material to be used, and the methods of identification and control
of the reworked products.
The reworked/repaired products, when applicable, shall be
clearly identified and traceable. The reworked/repaired products
shall be reinserted into the principal flow at the point previous
to where the n checked with the same gauges or test equipment that
discovered the non-conformity.
7E Non-conforming products management
Non-conforming parts shall be adequately identified via
signs/documents and properly segregated (well delim containers).
There shall be defined rules for the management of non-conforming
products and relevant responsibilities:
- identification; - segregation; - re-work/repair; - re-check; -
reject or scrap; - deviations. When a non-conformity is discovered,
the relevant management procedure shall be correctly applied
(segregat the causes, corrections on processes, control of
effectiveness of corrective actions).
8 LOGISTIC 8A Traceability Traceability shall be guaranteed for
safety components and/or for components subject to specific
regulation.
When the components have characteristics classified as
Safety/Report or subject to homologation, it sha inspections and
tests according to what is agreed with the customer and according
to what is required by variou Norm 9.01102).
There shall be a traceability link between the packaging label
and the product, lot, packing list, quantity, revis controls used
both in internal and external processes.
Lot traceability to the raw material and/or sub-supplier
components shall be maintained when required by contr
PCPA GUIDELINES
There shall be a clear identification of the batches assigned to
Quality Department inspections/checks.
When it is required, on the finished product shall be reported
the Supplier's alphanumeric code, with proper mo 07611. Materials
stored in stock shall be rapidly identifiable by means of
documentation reporting codes and lot numbe
There shall be adequate procedures for the management of any
modification concerning the product, proces shall be shown through
a correct management of product/component modifications. Any
product produced before a modification shall be considered as
non-conforming unless otherwise provided
8B Identification
The identification tag/label shall be visible for materials in
stock. All semi-finished and/or finished products shall be
positively identified (e.g. part number, lot code, quantity) a
respect to the different phases of the manufacturing cycle
(operations completed). The application and appropriateness of the
provisions to visualize the inspection status (e.g. color coded
tags) - product waiting to be inspected; - product inspected and
accepted; - product waiting for a decision; - non-conforming
product; - waste product (scrap) (segregation/identification in
order to avoid any re-insertion into the process). The rejected
product area, where the non-conforming material is stored waiting
for its final destination, must personnel. Identification
conditions shall be commensurate to the risk and type of process.
Identification may be related to every single piece, to the
container or the work cell, and shall enable to concerning
inspections, gauges/test equipment, operator, date, team, etc.
Identification shall be clear, even after the partial use of the
lot. Consistency between identification and traceability
requirements shall be guaranteed in particular for products w
Each box, container, packaging, etc. shall be identified.
Periodic controls shall be carried out to ascert correspond.
Non-conforming products shall be identified and segregated in the
relevant areas. Product identification/marking shall comply with
the customers specifications and has to be written, in cas
assembly, if they are available loose on the spare parts market.
The auditor shall ensure all packaging is properly identified. 8C
FIFO There shall be a system guaranteeing FIFO throughout the
process flow.
PCPA GUIDELINES
Is the expiration date for perishable products managed? Product
lots shall be sent to the following operation in an organized
manner (FIFO, identification of destination If there is an
Information Retrieval System, in the event of a failure, FIFO shall
be managed by means of an eq
8D Appropriate handling and packaging
Product storage areas at each workstation shall be commensurate
to requirements. Packaging used shall be designed to assure, even
in the case of repackaging, the integrity of the single compo
Packaging shall be identified according to standards agreed with
the customer (packaging specifications). Operating instructions
shall be defined in case of damaged packaging.
During unloading, staging and storage operations, environmental
conditions shall be such as to protect the inte Handling, transport
and containing means (forklifts, transpallets, etc.) shall be
efficient and operated under safe
Storage shall be done on pallets, shelves, etc.; these shall be
suitable and in good conditions: cleaning, mainte piling to ensure
safety and product integrity. Storage/stockpiling areas shall be
sufficiently sized to contain the material, located in a logical
way with re protect the product, with easy access and safe
handling. The supplier shall not use customer containers/packaging
for internal handling.
8E Appropriate process flow
The technical documentation to be used in the workstations shall
be easily accessible without disrupting the wo Material flow shall
be designed to avoid missing of operations or mix of parts with
similar products.
Equipment for production of lots/work orders not currently under
production shall be properly identified a management of
components/products being manufactured. Review the actual
manufacturing area against the Process Flowchart, general layout
and process control p Receiving to Dispatch. The workplace should
be configured as per the general layout and be provided with
adequate space, lighting, e
Locations should be designated and, where necessary, secured for
the storage of gauges, scrap, reworked par
Provisions should also be made for display of Process Control
Plans, Standard Operation Sheets, Work Instruc etc.
9 CONTINUOUS IMPROVEMENT 9A Lessons Learned
PCPA GUIDELINES
Are the issues found on current product managed and analyzed?
Are the relevant corrective actions implement
9B Improvement Activities for Tier 2 Suppliers
Does an improvement plan related to tier 2 suppliers exist, in
order to improve the quality of their product/proce
9C Warranty
Are developed analysis/prevention system that allow to prevent
and avoid any claim from field? Are managed and analyzed the data
related to problems detected in field? Are the samples returned
from field analyzed (SITRA cards etc.)? Are Corrective Actions
related to those analysis implemented? Does a system for collecting
and stratification of data exist (QT, TESIS, SITRA, etc.)? Are the
qualified tier 2 suppliers involved in the above mentioned
activities going back up the processes an activities transferred to
the new products in development?
9D Periodic Re-Qualification
Periodic process reviews and/or audit shall be performed in
order to assure the maintenance over ti qualification/approval of
the process. A periodic re-qualification of the supplied system,
assembly or component shall be planned, with frequencies sh
In case there is not a specific request by the customer, the
supplier shall arrange a plan by itself with frequency
The re-qualification process shall include all the necessary
tests for the self qualification of the system, asse C.C.Q.
(Certificate of Quality and Conformity). They are the tests that
are written into the shared Self Qualificat
9E Quality and Environmental certifications
The auditor shall require to supplier copy of its Quality System
Certificate and Environmental Management C equivalent).
ONE PAGE REPORT N ___Project: Part Description: Part Number:
Prod. Family: Date: Sprayer - Hood Hood - Fuel Tank 87271096
9/11/2008 ODM: Supplier Name: Supplier Code: Manufact. Plant:
SQE:
Supplier QualityFIACBRAS BKQ52 Sumar (SP) R. Mximo (vx822)
Abstract up to 3 arguments in order of severity:
1 3 5
BACK TO PCPA FORM
Argument:
(Program Review 1, 2, 3, etc., PCPA 1, 2, 3 etc., OK to samples
or batches for Process Verification, Pre-series, etc.)
Problem / Root cause:
Containment / Corrective Actions: (Insert responsible and
date)
Timings: 1st Try out: 1st Part: Interim:
Self-qualification:PROCESS VERIFICATION (VP)
CW 12 Sampling for Benestare: CW 14 Sampling for Integr. Tests:
CW15 Batch VP, Pre-Serie: CW 27 PRE-SERIES (PS) SQE Coord. Buyer
E&D RELEASE TO PROD. (DaP) Project Coord. Sviluppo Supplier
CURRENT PRODUCTION SQM Piattaforma
CW 22 CW 21 CW 15
Distribution: SQD QPL
