VIA Supplier Quality Manual April 11 13

Doc #: 740-02-05 R1 04/11/13 VIA Supplier Quality Manual

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ACKNOWLEDGEMENT

The VIA Motors Supplier Quality Requirements were developed in reference to the Automotive Industry

Action Group (AIAG) and ISO 9001:2000/TS16949 requirements and procedures.

VIA Motors understands that suppliers can have questions regarding these requirements from time to time

over the course of our partnership. Suppliers are encouraged to contact a VIA Motors Supplier Quality or

VIA Supply Chain representative for clarification of any standards.

This manual is a controlled document. No changes or revisions to be made unless submitted by VIA Motors

Inc.

Latest Revision Date:_ 04/11/13

Revision Number: Rev 1

VIA Document Control number: 740-02-05

Revision Section Reason for Change Date

0 All Initial Release 12/19/12

1 1,3,5,6 Update and Doc control # addition 04/11/13


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TABLE OF CONTENTS

1 Introduction ...................................................................................................................................... 3 1.1 Purpose of Supplier Quality Requirements (SQR) ......................................................................................................................... 3 1.2 Scope ................................................................................................................................................................................................................... 3 1.3 Expectations .................................................................................................................................................................................................... 3 1.4 Supplier Involvement (ref. ISO/TS16949 7.3.1) ............................................................................................................................. 4 1.5 Verification of Requirements .................................................................................................................................................................. 4 1.6 Supplier Performance Rating System (SPRS) (ref. ISO/TS16949, sect. 8.2) ..................................................................... 4 1.7 Additional Resources .................................................................................................................................................................................. 4

2 Advanced Product Quality Planning (APQP) ........................................................................................ 5 2.1 APQP Tools ....................................................................................................................................................................................................... 5 2.2 APQP Checklist and Status Reporting (ref. ISO9001/TS16949 7.2.3) .................................................................................. 5 2.3 Milestone Reviews ........................................................................................................................................................................................ 5 2.4 Packaging (ref. ISO9001/TS16949 7.5.5) ......................................................................................................................................... 6 2.5 Measuring Devices (ref ISO9001/TS16949 7.5.4 and 7.6) ........................................................................................................ 6 2.6 Customer-Owned Supplier Tooling (ref ISO9001/TS16949 7.5.4) ........................................................................................ 6 2.7 PPAP master sample and Boundary Samples (ref ISO9001/TS16949 8.3) ....................................................................... 6 2.8 FMEA development (ref ISO9001/TS16949 7.3.3) ........................................................................................................................ 7 2.9 International Material Data System -IMDS (ref ISO9001/TS16949 7.3.6) ....................................................................... 7 2.10 Annual Validation Requirements (ref ISO9001/TS16949 7.5.2) ......................................................................................... 7 2.11 Preventative Maintenance (ref ISO9001/TS16949 7.2.1, 7.5.1) .......................................................................................... 8 2.12 Control Plan Development (ref ISO9001/TS16949 7.5.1) ...................................................................................................... 8

3 Sample Submission Production Part Approval Process -PPAP (ref ISO9001/TS16949 7.3.6) .................. 9 3.1 Procedure ......................................................................................................................................................................................................... 9 3.2 Product and Process Changes ................................................................................................................................................................. 9

4 Problem Resolution (ref ISO9001/TS16949 8.5.2).............................................................................. 10 4.1 Introduction ................................................................................................................................................................................................. 10 4.2 Corrective Action Initiation: Non Conformance Report (NCR), Improvement Reports (IR) and 8 Disciplines

Report (8D). .............................................................................................................................................................................................................. 10 4.3 Supplier Response ...................................................................................................................................................................................... 10 4.4 Charge Back Policy ................................................................................................................................................................................... 12 4.5 Controlled Shipping .................................................................................................................................................................................. 12

5 Initial Parts Production Tags - IPP (ref ISO9001/TS16949 7.5.3) ......................................................... 13

6 Quality System Certification and Compliance Requirements ............................................................. 14 6.1 Quality Management System requirements.................................................................................................................................. 14 6.2 Second Party TS16949 compliance approval guidelines – .................................................................................................... 14 6.3 Original Equipment Manufacturers (OEM) Approval List (ref ISO9001/TS16949 7.4.1) ....................................... 15 6.4 Record Retention Requirements (ref ISO9001/TS16949 4.2.4) ........................................................................................... 15

APPENDIX A: APQP & PPAP Requirements, Elements and expectations and checklist ............................. 16

APPENDIX B: Initial parts production control sheet ................................................................................ 31

APPENDIX C: Improvement report, NCR report, 8D form, guidelines for rootcause analysis and checklist,32

APPENDIX D Supplier Pre-selection and Performance Rating System ...................................................... 48


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1 Introduction

At VIA Motors, we clearly recognize the critical role quality plays in our success. We are, therefore, committed to meet our customer's quality needs and expectations with excellence by pursuing continuous quality and productivity improvements. A large segment of our quality performance is, of course, dependent on you as our supplier.

In this light, quality is a prime consideration for supplier selection and sourcing at VIA Motors. Your dedication to quality and strict adherence to VIA Motors Supplier Quality Requirements will clearly document your value as a VIA Motors supplier.

The expectations, requirements and standards defined within this manual are applicable to

all suppliers providing materials, products and services to any VIA Motors facility. This includes suppliers of direct materials, packaging materials and services (including containment, sorting and calibration services) with potential impact on any

product characteristics affecting VIA Motors’ Customer requirements. These requirements also apply, in whole, to any supplier that is directed to VIA Motors, by any OE Customer.

1.1 Purpose of Supplier Quality Requirements (SQR)

The purpose of this SQR manual is to promote a clear understanding of VIA Motors’ expectations and requirements for suppliers. This manual contains the VIA Motors Customer Specific requirements which need to be integrated into each supplier’s Quality Management System along with ISO9001/TS16949 requirements.

1.2 Scope

These standards apply to suppliers of OEM production or service material to VIA Motors North American Operations (NAO).

1.3 Expectations

VIA Motors suppliers are viewed as being fully responsible for the quality and delivery of their products. Therefore, suppliers must ensure that all materials are produced in conformance to the required standards. Suppliers are expected to:

• Ship zero defects

• Provide timely corrective actions that permanently eliminate the defect in the event of a nonconformance

• Execute flawless launches and obtain Full PPAP Approval each submission

• Deliver the required quantity of product, on-time, with appropriate ASN, paperwork and labels

• Provide exceptional service to each VIA Motors division and department

• Provide competitive pricing to win new business

• Remain competitive through continuous improvement of costs during the program

• Provide sustainable ideas for cost reductions

• Provide quotations using the VIA Motors RFQ format

• Adhere to the VIA Motors International Terms and Conditions

• Inform ISO9001 and TS16949 certification bodies (e.g. 3rd party registrars) of these


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requirements prior to certification or re-certification audits so they may be included in the audit process

Additional information concerning delivery requirements is located in the VIA Motors Packaging and Shipping Requirements Manual. Additional information concerning commercial expectations can be found in VIA APQP/PPAP requirements and checklists.

1.4 Supplier Involvement (ref. ISO/TS16949 7.3.1)

VIA Motors suppliers have an obligation to establish a cross-functional team to manage the product planning process. Suppliers must expect the same performance from their subcontractors. VIA Motors expectations regarding planning for quality are described later in this manual.

1.5 Verification of Requirements

VIA Motors reserves the right to audit contracted products and applicable processes/systems associated with those products at the suppliers’ premises. VIA Motors also reserves the right to allow its customers to audit those same products/processes/systems.

1.6 Supplier Performance Rating System (SPRS) (ref. ISO/TS16949, sect. 8.2)

VIA Motors intends to establish and maintain long-term relationships with suppliers

who are committed to continuous improvement in quality, cost, delivery and service in the hybrid and electric vehicle development. The VIA Motors Supplier Performance Rating System (SPRS) is a means to provide feedback on performance against the expectations described in section 1.3. VIA will be using this tool to help identify opportunities for continuous improvement and improve customer satisfaction. Therefore, suppliers are expected to incorporate SPRS results into the measurement, analysis and improvement process of their Quality Management System.

The SPRS system is an supplier rating against VIA PPAP requirements. SPRS

report cards are to be reviewed by VIA with suppliers to view performance feedback. Historical reports are archived at VIA Motors. For additional questions concerning Vendor Survey, Initial qualification and SPRS, contact your VIA Motors Purchasing representative or VIA MOTOR’s Contract Manufacturers or Purchasing representative or Supplier Quality Representative.

1.7 Additional Resources

For further explanation of the VIA Motors Supplier Quality Requirements Manual, contact your VIA Motors Supplier Quality Assurance Representative or VIA SQE. Also please refer to the Automotive Industry Action Group (AIAG) reference documents including Failure Mode and Effect Analysis, Advanced Product Quality Planning and Control Plan, Production Part Approval Process, Statistical Process


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Control, Measurement Systems Analysis and Quality Management Systems for further details (www.aiag.org). Suppliers are expected to have document control systems in place to ensure that the latest released version of the AIAG reference document is being used.

2 Advanced Product Quality Planning (APQP)

Product quality begins at design. Therefore, from initial product concept through production and service, the supplier and VIA Motors must understand and agree on all applicable engineering, design and quality standards and requirements. Agreement must be reached on all critical characteristics, control items, annual layout and validation requirements, check fixtures, packaging requirements, and all other quality related matters. These agreements need to be driven by the supplier for all parts, materials and services and documented using the APQP tracking tools listed below.

2.1 APQP Tools

VIA Motors requires that suppliers use the advanced quality planning techniques (as they apply) described in the AIAG Advanced Product Quality Planning and Control Plan manual.

2.2 APQP Checklist and Status Reporting (ref. ISO9001/TS16949 7.2.3)

2.2.1 The supplier shall track and communicate program development activities using the VIA Motors APQP matrix and checklist. Updated APQP Matrix/Gap Analysis reports and supporting evidence shall be submitted to the VIA Motors Quality Engineer upon request. Program timing requirements will be established by the VIA Motors Program Team based on the VIA Motors Program Management and customer requirements. Optional formats may be used if approved by the VIA Motors Program Quality Representative.

2.3 Milestone Reviews

2.3.1 VIA Motors may choose to perform Milestone Reviews (MSR) of the supplier’s APQP process during the program development stages. MSR meetings will consist of a review of the APQP matrix and supporting evidence as described in 2.2.1 above by VIA Motors Program Team members. This process may also include a production readiness evaluation such as the VIA Motors Run-at-Rate. VIA Motors may also choose to utilize customer-specified formats based on customer requests such as GM’s Process Sign-Off, General Motors Run-at-Rate, Honda Are-You-Ready or others.

2.3.2 MSR meetings will be established through your VIA Motors Program Manager


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or Release Engineer.

2.4 Packaging (ref. ISO9001/TS16949 7.5.5)

2.4.1 Suppliers are required to meet the guidelines established in the VIA Motors Packaging and Shipping Requirements as defined by the drawing and specs and agreed upon during PPAP qualification process with the VIA motors Quality or Purchasing Representative.

2.5 Measuring Devices (ref ISO9001/TS16949 7.5.4 and 7.6)

2.5.1 Suppliers are responsible to supply gauges for their own use to ensure only product that meets design specifications and all quality requirements is shipped to VIA Motors. All customer-owned gauges and fixtures shall be identified as property of the purchaser per the purchase order terms and conditions. All other gauges and fixtures shall be the supplier’s responsibility.

2.5.2 The supplier shall be responsible for the following:

2.5.2.1 Design of the gauge.

2.5.2.2 Acquire gauge design approval from the VIA Motors Release or Quality Engineer.

2.5.2.3 Successfully complete a measurement system analysis per the AIAG Measurement Systems Analysis (MSA) Manual. Refer to the MSA Manual for acceptable gauge R&R criteria.

2.5.2.4 Maintain the gauge calibration for the life of the program.

2.5.3 Upon program completion, the supplier shall ensure gauges are properly stored to prevent any damage and are readily available for service requirements.

2.6 Customer-Owned Supplier Tooling (ref ISO9001/TS16949 7.5.4)

2.6.1 All customer-owned tooling shall be identified and maintained per the purchase order terms and conditions for the life of the program.

2.6.2 Upon program completion, the supplier shall ensure tooling is properly stored to prevent any damage and is readily available for service requirements.

2.7 PPAP master sample and Boundary Samples (ref ISO9001/TS16949 8.3)

When cosmetic issues arise that cannot be addressed by use of the "master samples," the supplier is responsible for establishing approved boundary samples with VIA Motors prior to shipping questionable product. PPAP samples shall serve as the “master” for comparison purposes. All “max go” boundary samples require VIA Motors Quality Engineering approval prior to implementation. Standards that


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identify non-conforming conditions which are not to be shipped do not require VIA Motors approval.

2.8 FMEA development (ref ISO9001/TS16949 7.3.3)

VIA Motors requires suppliers to utilize the latest release version of the AIAG

Potential Failure Mode and Effects Analysis reference manual. Please refer to this manual for development guidance, rating criteria and quality objectives.

When the severity of a failure mode is 9 or 10, special attention must be given to

ensure that the risk is addressed through existing design actions/controls or process preventive/correction action (s), regardless of the RPN. Once all severity rankings are lowered, the supplier team should be addressing other failure mode rankings in occurrence, and then detection. VIA Motors expects that our suppliers will use the FMEA as a living tool. The FMEA documents should always reflect the latest level as well as the latest relevant actions.

2.9 International Material Data System -IMDS (ref ISO9001/TS16949 7.3.6)

VIA Motors has adopted the requirement of reporting all substances that are present

in all Vehicles we supply to our customers in the automotive market. As a condition of conducting business with VIA Motors, suppliers must also meet this requirement.

In order to implement a pro-active system for meeting this requirement, suppliers are required to provide the appropriate supporting documentation with the first shipment or sample to VIA Motors Procurement Department. This documentation is required prior to the time of PPAP submission. Failure to provide the information of the IMDS may result in your PPAP submission being returned without evaluation, given rejected status or given limited approval status. Tooling payment may also be impacted due to failure to comply with IMDS requirements. For specific timing of submission requirements please contact the appropriate VIA MOTORS Engineering/Program Management or Purchasing representative that is designing or procuring the part in question.

2.10 Annual Validation Requirements (ref ISO9001/TS16949 7.5.2)

The supplier is responsible for performing annual layout, performance and material validation for each part number produced based on the VIA Motors approved drawing and other agreed upon engineering requirements of the PPAP. Extent of the validation will be determined and agreed upon during the APQP process and reflected on the supplier’s Control Plan. Validation results will be retained at the supplier’s location and available for review by the VIA Motors upon request. The supplier must notify the appropriate VIA Motors Supplier Quality Engineer, when review of the data shows non-conformances. Contact your VIA Motors Program Manager, Release Engineer or Quality Assurance representative with any questions concerning annual layout/validation requirements.


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2.11 Preventative Maintenance (ref ISO9001/TS16949 7.2.1, 7.5.1)

Preventative Maintenance (PM) plays an important role in achieving and maintaining quality objectives. Identification of safety <MDS> and critical <MDC> characteristics in the PM system will allow the supplier to ensure proper controls are in place to closely monitor the PM process with a focus on these features. Suppliers are required to identify PM process steps that can affect safety or critical characteristics and ensure these steps are controlled. This information should be reflected in the APQP and PM Standard Work documents.

2.12 Control Plan Development (ref ISO9001/TS16949 7.5.1)

VIA Motors requires suppliers to utilize the latest version of the Automotive Industry Action Group Advanced Product Quality Planning and Control Plan reference manual. Please refer to this manual for development guidance for your Prototype, Pre-Launch and Production Control Plans. Suppliers are required to provide the various levels of Control Plans based on the expected program builds. The Control Plans are subject to review and approval by VIA Motors. Control Plan requirements are listed below.

Prototype Control Plan - The prototype phase of the product quality-planning period is to effectively assess the product design and development for meeting all of the customer’s requirements for fit, function, and durability. The focus will be on dimensional, functional (including subcontracted processing) and statistical analysis of all products shipped for the various prototype builds. The intent is to provide a heightened level of data analysis to support the design validation activity. Unless otherwise specified, this includes numbering/sequencing of parts and data for 100% of all product shipped during this phase of the program launch.

Pre-Launch Control Plan - The pre-launch phase of the product quality-planning period is to effectively assess the process design and development for meeting all of VIA’s or VIA’s customer requirements for fit, function, appearance, and durability. The focus will be on the entire process stream, with an increased level of inspection and performance testing (including data analysis) put in place to verify the effectiveness of the process to produce zero defects. This increased level of verification is called launch containment at VIA Motors. The control items to be managed and reported through the launch containment process need to be agreed upon with your VIA Motors Program Manager/Release Engineer or Quality Engineer. The Pre-launch Control Plan would take effect at the completion of the prototype phase. If there is no prototype phase the pre-launch control plan would be implemented as the initial control plan. The pre-launch control plan remains in place until launch containment has verified effectiveness of the production control system. The duration of this control plan will be determined based on the actual results of the supplier to achieve the expected quality requirements for the product being supplied.


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Release from the pre-launch control plan can only be authorized by the VIA program Manager, Procurement or Quality Representative.

Production Control Plan - This control plan is an extension of the pre-launch control plan incorporating lessons learned from the launch. It defines the inspection and testing systems required to meet VIA Motors requirements for production. It also includes checks related to shipping and packaging. Transition from the pre-launch to production control plan requires VIA Motors approval.

3 Sample Submission Production Part Approval Process -PPAP (ref

ISO9001/TS16949 7.3.6)

3.1 Procedure

As a VIA Motors supplier, you are responsible for performing the inspection and testing to verify conformance to all applicable product requirements. Submission is to be made according to the AIAG Production Part Approval Process (PPAP) manual. Submissions to VIA Motors US facilities are to be made in the English language unless specified otherwise by the VIA purchasing division. Submissions to the VIA Motors LATAM may be made in Spanish or English, preferably in both. Please contact your VIA Motors division Quality Engineer with questions concerning PPAP submission status.

You are not authorized to begin production or ship material to VIA Motors prior

to PPAP approval unless an approved waiver has been granted by the VIA

Motors Procurement, Release Engineer or Quality team.

3.2 Product and Process Changes

All proposed design and process changes, including any changes of or at your supplier site(s), must be submitted to the appropriate VIA Motors Quality Engineer or SQE for approval prior to implementation using the suppliers or VIA Engineering Change Request form. Suppliers are not authorized to make product/process changes without SECR approval. Upon receiving SECR approval, PPAP requirements must be agreed with the VIA Motors division Quality Engineer. A copy of the approved SECR is to be provided with the PPAP submission.


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4 Problem Resolution (ref ISO9001/TS16949 8.5.2)

4.1 Introduction

VIA Motors suppliers are responsible for providing defect-free product on time and at the specified quantities to VIA Motors and ultimately our customers. When quality or delivery issues do occur, the supplier is required to initiate problem-solving and corrective action to resolve the issue and prevent recurrence as soon as reasonably possible.

This section covers the VIA Motors specific requirements for problem-solving and corrective action reporting. It is designed to guide VIA Motors suppliers in the development of a corrective action system that will meet VIA Motors’ minimum requirements. It is to be used in conjunction with ISO/TS16949 requirements for corrective action

VIA Motors requires that a systematic, team-oriented problem-solving method be utilized. The team is required to implement short-term and long-term corrective action plans and verifies the effectiveness of the corrective action taken to prevent recurrence using a structured problem solving and statistical methods. Please contact the VIA Motors SQE or VIA’s Procurement representative for further assistance in team-oriented problem-solving methods and whenever possible use VIA motors Improvement and 8D forms.

4.2 Corrective Action Initiation: Non Conformance Report (NCR), Improvement Reports (IR) and 8 Disciplines Report (8D).

The supplier will be notified of defective material through a phone call/email from VIA’s Quality or Procurement Group and if the problem is significant enough receive a VIA Motors CAR, NCR, IR or 8D depending on the severity of the issue at hand. The supplier is expected to use and understand Corrective Action Report (CAR), Improvement Report (IR) or Non Conformance Report, (NCR) or similar 8D-type reporting tools. The CAR, NCR or IR is a document issued by VIA Motors when purchased material is identified as not meeting the quality requirements.

Defective material may be identified at VIA Motors during incoming inspection, assembly, or packaging. The material can also be discovered during an audit, validation, at the customer or through warranty returns.

VIA Motors will supply as much information as is available to us of the header portion of the CAR, NCR or IR and review it for completeness prior to issuing the CAR, NCR or IR to the supplier. The supplier completes the Root Cause Analysis, Containment, Corrective Action and Preventive Action part as well as the Verification depending on the form.

4.3 Supplier Response

Once the supplier has been notified of the nonconforming material issue, the supplier is required to complete the remaining portions of the CAR, NCR or IR form. Strict


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adherence to the forms is recommended as it is the predominant tool used at VIA Motors to evaluate the supplier response. If the supplier wants to use its own forms that is acceptable as long as the VIA Quality or Procurement representatives reviews and approves the use of such forms.

4.3.1 The following items require a written response within a 48-hour period

unless extended by VIA Motors. Follow the Improvement report or the 8D report for details, below is an overview:

4.3.1.1 Corrective Action Team or at least main contact established.

4.3.1.2 Identify and initiate a short-term containment plan to contain further nonconforming material from reaching the VIA Motors work cell. Reference the CAR, NCR or IR Checklist, section 3 in Appendix C of this manual.

4.3.1.3 Identify short-term actions with timing to replace nonconforming material with certified material.

4.3.1.4 The containment plan and verification method must be documented by the supplier on the CAR, NCR or IR and sent back to the issuing VIA Motors division along with any appropriate attachments. All attachments must reference the CAR, NCR or IR number.

4.3.1.5 Identify all potential root causes that resulted in the nonconforming material issue using tools such as fishbone diagrams, 5-why analysis, Is/Is Not comparison and Process FMEAs. Forward this analysis with the CAR, NCR or IR response (see CAR, NCR or IR Checklist, section 4.1 in Appendix C of this manual).

4.3.2 The following items require a written response by the Response Deadline field of the CAR, NCR or IR document unless approved by VIA Motors.

4.3.2.1 Corrective Action Team membership update

4.3.2.2 Define and verify the root cause (see CAR, NCR or IR Checklist, section 4.2). Depending on the severity and risk of the non conformance, VIA NCR form or VIA’s 8D form, VIA’s Improvement Report Form will be used for corrective action or preventive action and may be used by the problem solving team to help identify the true root cause.

4.3.2.3 Identify and implement permanent corrective action (see CAR, NCR or IR Checklist, section 5 and 6). Suppliers may be required to identify the initial shipments containing the action using the IPP tag (reference section 5).


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4.3.2.4 Verify permanent corrective action using statistical methods (see CAR, NCR or IR Checklist, section 7).

4.3.2.5 Update all relevant documentation that is affected to standardize corrective actions into the quality system (see CAR, NCR or IR Checklist, section 8).

4.3.3 VIA Motors may require the supplier to implement verification (audit) activities to confirm that corrective actions continue to be effective over a significant time period (30/60/90 days). Verification results are to be documented on the CAR, NCR or IR when requested.

4.4 Charge Back Policy

4.4.1 Costs associated with supplier part quality issues and PPAP rejection issues that are deemed the supplier’s responsibility will be charged back to the supplier.

4.4.2 The supplier may visit VIA Motors upon receipt of a CAR, NCR or IR to review the issue and accept or refute responsibility prior to being charged.

4.4.3 The supplier, if found responsible, will pay the costs associated with the quality issue at the prevailing VIA Motors rate (contact your VIA Motors Purchasing representative for current rates).

4.5 Controlled Shipping

4.5.1 General

Controlled Shipping is a requirement by VIA Motors that a supplier put in place a redundant inspection process to sort for a specific nonconformance, while implementing a root-cause problem solving process. This redundant inspection is in addition to normal controls and actions implemented via the corrective action requirements in section 4.3.1.2 above. Any additional cost associated with controlled shipping is the responsibility of the supplier. Any deviations to this requirement must be approved by VIA Motors.

VIA Motors may require the use of a third party contractor to conduct and manage the controlled shipping activity. A third party containment process is generally required when the supplier’s own containment process has proven to be ineffective. The third party contractor may be directed by VIA Motors. If the third party contractor is selected by the supplier, VIA Motors maintains the right of approval for the supplier selected. The data obtained from the third party redundant inspection process as well as any additional audits are critical as both a measure of the effectiveness of the secondary inspection process and the corrective actions taken to eliminate the initial nonconformance. The Controlled Shipping inspection may be required to be performed outside the supplier’s facilities at a facility deemed appropriate by VIA Motors.


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4.5.2 Determination in enacting Controlled Shipping

VIA Motors makes the determination whether the supplier can effectively correct the nonconforming material situation through the CAR, NCR or IR process and isolate VIA Motors from the problem. One or several of the following issues may be considered for implementation of Controlled Shipping:

• Repeat, late or insufficient response to CAR, NCR or IRs

• Supplier’s current controls are not sufficient to ensure conformance to requirements

• Duration, quantity, and/or severity of the problem

• Internal/External Supplier data

• Major Disruptions and or Downtime

• Quality Problem in the field (i.e. Warranty)

• OEM customer required containments

• Expiration/lapse of third party Quality Management System certification - see section 6 of this manual for QMS certification/compliance requirements

4.5.3 Controlled Shipping Process

The following steps will take place when VIA Motors places a supplier in Controlled Shipping:

• VIA Motors will notify the supplier that Controlled Shipping is required. An explanation for the requirement and description of the process steps will be reviewed at this time. The required third party provider, if applicable, is also communicated.

• The supplier confirms requirements are understood and provides a plan of action to implement the Controlled Shipping process. Planned reporting mechanisms are also presented at this time by the supplier.

• VIA Motors reviews the plan and approves or rejects it. If the plan is rejected, VIA Motors provides feedback on adjustments required.

• Upon plan approval, VIA Motors provides exit criteria to supplier. The duration of Controlled Shipping will typically be 20 days following implementation of permanent corrective actions as described in section 4.3.2.3 above.

5 Initial Parts Production Tags - IPP (ref ISO9001/TS16949 7.5.3)

5.1 The Initial Part Production tag is a tool used to identify changed or special material so VIA Motors may have accurate approval and tracking records of any changes that occur to our product.

5.2 The tag must be attached to containers in the first shipment of the changed material. Please contact a VIA Procurement or Quality representatives with questions.

5.3 Creating the IPP tag


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5.3.1 Print the master tag onto 8 ½” x 11” yellow papers. Alternative size paper can be used based on box size.

5.4 Information required on tag

5.4.1 Part name as shown on drawing

5.4.2 Part Number: VIA Motors part number

5.4.3 Supplier Name

5.4.4 Description of change - document the SECR# and/or CAR, NCR or IR#

5.4.5 Revision Level: Revision level of tagged material

5.4.6 Date: Date of shipment

5.4.7 VIA Motors Facility: VIA Motors division designation or location.

5.5 Attaching IPP tag

5.5.1 Attach tag to each container next to the container label. The tag must be clearly visible.

6 Quality System Certification and Compliance Requirements

6.1 Quality Management System requirements VIA Motors requires suppliers to implement and maintain a Quality Management System (QMS) which meets the requirements set forth in this manual, with the goal of being compliant to TS 16949:2002. At a minimum, suppliers need to be registered by an accredited third party to the ISO 9001:2008 series standard with documented plans to achieve TS16949 compliance. Suppliers which do not manufacture product such as distributors are not eligible for TS16949 certification.

Suppliers shall include VIA Motors in the listing of customers provided

to the registrar prior to ISO9001:2008 or TS16949 audits along with access to this

manual and performance results in the VIA Motors Supplier Performance Rating

System.

6.2 Second Party TS16949 compliance approval guidelines – Supplier certification to TS16949 is the preferred method for VIA Motors suppliers to demonstrate conformance to the TS16949 technical specification. However, assessment by an OEM or an OEM approved second party will also be recognized as meeting the compliance requirements for TS16949 above.


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6.3 Original Equipment Manufacturers (OEM) Approval List (ref ISO9001/TS16949 7.4.1)

6.3.1 VIA Motors suppliers are required to use VIA Motors’s customer approved material and Contractor lists whenever applicable or possible. Please contact your VIA procurement representative to get a list of VIA’s approved suppliers or to get one of your supplier approved. Typical OEM approved supplier lists for VIA Motors products include, but are not limited to, suppliers providing, power electronics and its components, cooling system parts, bracket fab, heat treat services, plating services, paint or painting services. Review all VIA Motors and OEM specifications carefully on your drawing and purchase contract to identify required use of OEM approved contractors. Contact a VIA Motors Procurement representative with any questions on material selection. If required, VIA Motors will assist suppliers in the OEM approval process.

6.3.2 Suppliers may also be impacted by OEM Customer Specific requirements listed in TS16949 as these requirements are applicable throughout the supply chain. Customer Specifics can be located through the internet at: http://www.iaob.org. 6.3.3 Special Process Assessments (ref ISO9001/TS16949 7.3.5, 7.4.1, 8.2.2)

6.3.3.1 Suppliers and subcontractors providing coating services to products

supplied to VIA Motors which are used in Chrysler, Ford or General Motors products shall demonstrate compliance to CQI-12 Special Process: Coating System Assessment published by AIAG. All applicable coating processes shall be assessed annually using the CQI-12. All “not satisfactory” and “needs immediate action” results must be addressed for root cause and corrective action. The corrective actions must include risk containment to immediately protect VIA Motors and our customers. Long term actions shall be completed within 90 days unless approved by your VIA Motors Supplier Quality Engineer. Records of results and actions taken shall be made available to VIA Motors through posting the results on MDSC. Contact your VIA Motors Quality Department upon completion of results and any required corrective actions.

6.4 Record Retention Requirements (ref ISO9001/TS16949 4.2.4)

6.4.1 Production part approvals, tooling records, purchase orders and amendments shall be maintained for the length of time that the part (or family of parts) is active for production and service requirements plus one calendar year unless specified otherwise by VIA Motors. This requirement includes purchase orders for VIA Motors or VIA Motors customer-owned tooling.

Quality performance records (e.g. control charts, inspection and test results)

shall be retained for at least one calendar year after the year in which they were created.


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Records of internal audits and management review shall be retained for three years.

APPENDIX A: APQP & PPAP Requirements, Elements and expectations and

checklist

1. APQP Matrix

Supplier APQP Requirements Matrix

MY/Program: Actual" status symbol

Supplier Name: key:

Part Number(s)

Part Name: Supplier

Champion: note: ∆ & Χ

phone/e-mail

Magna Donnelly Program Management Process (PMP) Stage

MSR 4.1- date xx/yy/zz MSR 4.2- date xx/yy/zz

APQP Elements Target Actual Target Actual

1. Design FMEA

Preliminary DFMEA created for supplier responsible components or supplier has reviewed Magna Donnelly (MD) DFMEA. High RPN’s have action plans with timing

)

DFMEA reviewed and signed for

supplier responsible components or

supplier has reviewed MD DFMEA.

High RPNs have action plans with

timing that meets tool kick-off date.

2. Design Review)

Initial design review complete with supplier and MD per AIAG A-2 or equivalent

)

100% design concerns addressed. AIAG A-2 checklist or equivalent complete and

open issues resolved

3. Design Verification Plan

Agreement with MD on performance and functional validation plan; Identify key dimensional characteristics for layout on prototypes

)

Prototype testing and measurement is 100% complete.

4. Master Timing Plan

Major program elements are documented to meet the program deliverables.

)

Major program elements are

documented to meet the program

deliverables.

5. Facilities, Tool and Gauges

Tool lead time/maker concept gauge and fixture design concepts

Capacity study complete Supplier manufacturing facility identified

)

Tool maker and lead time fixed w/ schedule

Gauge plan complete and approved by MD

Machine/fixture plan complete and approved

6. Prototype Build Control Plan

Control plan contains DV test plan elements and prototype layout requirements

)

Prototype build issues fed back into pre-launch control plan.

7. Prototype Builds

Prototype build requirements are documented and agreed with MD (quantity, dates, lead time)

)

prototype parts delivered on time at

quality level expected. Build issues have been addressed.

8. Design Verification Testing

Surrogate test data submitted to MD Engineering and QA if available

)

DV failures were addressed in the

DFMEA and corrective actions

incorporated into the design.

DVP&R includes requirements form

all pertinent specifications


Page 17 of 48

9. Prototype Part Layout and MDS/MDC Ppk

preliminary list of critical characteristics identified and agreed with MD Surrogate capability data reviewed with MD Engineering

)

layout information complete, process capability known and can meet drawing

tolerances or actions in place to resolve

10. Drawings and Specifications

CAD data reviewed for feasibility issues and submitted to MD.

)

Drawings and specifications released and verified against CAD data

Drawings contain appropriate material and performance requirements

Drawings contain critical and safety characteristics

11. Team Feasibility Commitment

Team Feasibility Commitment has been reviewed by team and signed off as approved

)

Signed off to current design level

12. Manufacturing Process Flow Chart

)

Initial process flow is complete; used to develop PFMEA and Control Plan. AIAG checklist A-6 or equivalent initiated and

open issues identified with actions

13. Process FMEA

)

PFMEA reviewed with Magna Donnelly and signed. High RPNs have action plans with timing. AIAG checklist A-7 or

equivalent has been initiated and open issues identified.

14. Measurement Systems Evaluation

Plan for measurement of prototype parts exists and agreed with MD. Requirements for Gauge R&R agreed with MD

)

Gauge R&R complete for prototype as agreed in phase 4.1. Concerns with

measurement system addressed in production gauge or fixture design.

15. Pre-launch Control Plan

)

16. Production Ramp-up Schedule

)

17. Packaging Specifications (PKG Declaration)

Prototype packaging concept approved with MD

)

Production packaging plan reviewed with MD

18. Production Control Plan

)

19. Production Trial Run

)

20. Production Part Layout

)

21. Launch Readiness Review Meeting

A launch readiness review has been conducted with MD to review status of program and deliverables listed above

)

A launch readiness review has been conducted with MD to review status of

program and deliverables listed above. AIAG checklist A-4or equivalent initiated

and open issues identified with actions and timing.

22. Preliminary Process Capability Study

)

23. Production Validation Testing

)

A test plan exists for PV testing including specifications, tests, sample size,

requirements, and test facility

24. Boundary Samples

)

25. Production Part Approval (PPAP)

)


Page 18 of 48

26. Production Part Delivery at MRD

)

27. IMDS Data Entered into System

)

Design has been reviewed for compliance to ELV requirements. Concerns have

been reviewed with MD Engineering.

Supplier

Management

Approval

* Overall program rating - GREEN, YELLOW or RED

* Project Manager

* Top Management

2. Click here for a link to the Supplier Engineering Change Request (SECR) form

Appendix A, Attachment 1

APQP ELEMENT EXPECTATIONS

The following section describes VIA Motors expectations for each of the APQP elements found on the Advanced Product Quality

Planning (APQP) Matrix.

1. Design Failure Mode and

Effects Analysis

• Suppliers with Design Responsibility must create product specific DFMEA

• Others should request VIA Motors DFMEA & evaluate their products.

• Evaluation should include failure mode analysis, input to design controls, agreement with

action plans & timing.

• Review & Acceptance should be documented utilizing AIAG DFMEA Checklist (or

equivalent).

2. Design Reviews • Suppliers must provide evidence of design review being conducted with VIA Motors

(MD) Launch Team personnel

• Design Issues must be documented in some form of issues list tracking ownership &

completion.

• Review & Acceptance of design should be documented utilizing AIAG A-2 Checklist (or

equivalent).

3. Design Verification Plan • Evidence of agreement/approval from MD must be provided for:

• Performance Validation Plan

• Functional Validation Plan

• Dimensional Validation Plan

• Consideration of Measurement System Analysis for prototype and production

• MD approval


Page 19 of 48

4. Master Timing Plan • Master Timing Plan Minimum Requirements:

• Prototype Build Dates, Quantities, & Material Required Date at MD (MRD)

• Pre-Production Build Dates, Quantities, & MRD

• Production SOP Build Dates, Quantities, & MRD

• Tool Timing

• Equipment Timing

• Dimensional Validation

• Functional Validation

• Performance Validation

• Associate Training

• Sub-Supplier PPAP Timing

• PPAP Submission detailing Key Milestones such as Appearance Approval, etc.

5. Facilities, Tools, and

Gauges

• Self-explanatory on matrix

• Refer to AIAG APQP Manual Checklists

6. Prototype Build Control

Plan

• Includes Hand Assembly Operations

• Product Fit/Function Validation

• Product Layout

• See AIAG APQP Manual Appendix A Checklist

7. Prototype Builds • All VIA Motors prototype material required dates (MRD) will be met with the correct

level parts, customer specified data, and VIA Motors approval for any nonconformance.

8. Design Verification

Testing

• Design testing completed per DVP&R (item 3)

• All design deficiencies identified are updated in DFMEA, corrected, and retested

9. Prototype Part Layout

and MDS/MDC Ppk

• Include preliminary critical characteristic designation

• Include surrogate capability data for tolerance

• Product Fit/Function Validation prior to shipment

• Product Layout to occur prior to shipment

• Advanced notification & agreement of product not meeting specification prior to

shipment

10. Drawings and

Specifications

• Suppliers will work with VIA Motors to ensure engineering specification tests, and

product validation test requirements are documented in time to support pre-launch

control plan development.

• Suppliers will coordinate with VIA Motors the need to use VIA Motors’s customer

approved source lists.

11. Team Feasibility

Commitment

• Team Feasibility Commitment has been reviewed by team and signed off as approved to

current design level for all Milestone Reviews

12. Manufacturing Process

Flow Chart

• Process Flow Chart used to develop PFMEA and Control Plan.

• AIAG checklist A-5 or equivalent initiated and open issues identified with actions

• Launch containment is addressed in flow.

13. Process Failure Mode and

Effects Analysis

• PFMEA is Process Failure Driven, not Product Failure Driven

• PFMEA approved by VIA Motors.

• AIAG checklist A-7 or equivalent utilized in conjunction with AIAG FMEA manual

• Packaging, labeling and shipping are included in analysis.

14. Measurement Systems

Evaluation

• VIA Motors must be given the opportunity to review and concur with the gauge and test

equipment plans and actual study results

• Utilization of AIAG Measurement Systems Analysis Reference Manual for guidance on

utilizing statistical techniques to develop and qualify measurement systems.

15. Pre-Launch Control Plan • Pre-launch control plan approved by MD (also referred to as pre-production control plan)

• Launch containment is documented in plan

• AIAG checklist A-8 or equivalent is utilized

16. Production Ramp-up

Schedule

• The supplier will define their own Ramp up schedule to support the VIA Motors

Production Ramp-up Schedule.

• Supplier trained in use of VIA Motors Supplier Connection system prior to SOP


Page 20 of 48

17. Packaging Specifications • Packaging requirements will be agreed to by the supplier and the VIA Motors division

• Includes prototype packaging

• Production packaging approved via MD Packaging Declaration form

18. Production Control Plan • Production control plan approved by MD

• Launch containment is documented in plan if required

• AIAG checklist A-8 or equivalent is utilized

• Supplier has audited implementation of control plan in production environment

19. Production Trial Run • PPAP run complete with production process, tooling and equipment.

• Problems identified are quickly addressed with corrective actions

• Scrap rate and cycle time 100% to plan.

20. Production Part Layout • Part layout requirements agreed with MD in advance - number of pieces, dimensions, etc.

• Dimensional results approved by MD

• Out of Tolerance Items - actions to correct items should be complete prior to PPAP

21. Launch Readiness Review

Meeting

• Launch readiness reviews are conducted with MD to review status of program and

evidence to support ratings in APQP matrix. Run-at-Rate acceptable prior to SOP.

22. Preliminary Process

Capability Study

• PpK studies complete and meet PPAP requirements. Containment plans are in place and

documented on the control plan for unstable processes or PpK < 1.67

23. Production Validation

Testing

• All dimensional, material, functional, and reliability tests must be completed prior to

production part approval. If not, appropriate action plans and VIA Motors approvals are

required.

24. Boundary Samples • The Boundary Samples will be signed off by VIA Motors.

25. Production Part Approval • All items of the AIAG Production Part Approval Process manual must be completed and

the required documentation provided to VIA Motors with the Part Submission Warrant.

• All Results Must be ballooned to drawing, whether assembly or sub-component

• Type of device utilized to obtain data needs to be identified

• Provide evidence of service provider certification for layout and lab if external site used

• Include copy of specifications in PPAP submission

• Include evidence of sub-supplier PPAP approvals

• Additional information may be required that is MD facility-specific. Contact your MD

Quality Engineer in advance for additional requirements

26. Production Part Delivery

at MRD

• Production shipping schedules established to support MD requirements

• Delivery and frequency method agreed with MD

27 IMDS Data Entered into

System

• Suppliers are required to sign in to the IMDS system and log the information for the part.

See section 2.9 of this manual for more information on IMDS.


Page 21 of 48

VIA MOTORS SUPPLIER PPAP REQUIREMENTS

PSW PART

SUBMISSION

WARRANT

To clearly state to the Customer the reason for your submission. Take special note of the

following:

- Record part revision level to the right of the part# (Dwg revision & Part revisions may be different)

- Supplier Must mark “yes” or “no” to meeting all Dwg. Requirements & sign the PSW.

- Part Weight to be expressed in kilograms to four significant decimal places (0.0000).

Reminder- Part weight is determined by an average of ten randomly selected parts.

- Identify whether the part does or does not contain Reportable/Restricted Substances

- The specific Molds/component/Prod. Process' pertaining to the PPAP shall be ID'd on the PSW.

- Record the Production Rate at which the PPAP samples were produced on the PSW.

- All checking aides used in the everyday processing of a part shall be identified on the PSW.

APPEARANCE

APPROVAL

REPORT

For Appearance Items

ONLY

Submitted with PPAP and sample parts for the customer to sign, verifying parts are verifying that the parts

meet all aesthetic criteria.


Page 22 of 48

SAMPLE PARTS

SAMPLES FROM PPAP

RUN

Submitted for Appearance and Functional evaluation. Six samples are required

with each PPAP submission

- A few of the parts used for dimensional verification shall be submitted. These shall be labeled

with part, component, revision, tool#, etc. & with a sample number that corresponds to the Dimensional

Report. Suppliers shall submit samples that represent each unique component, mold, line, etc.

- Sample parts sent in shall be from a significant "production" run as outlined in the AIAG PPAP

Manual.

PROCESS/

PRODUCT

CONTROL

PLAN (C.P.)

To aid in the manufacture of quality products according to customer

requirements. A structured approach for the design, selection, and implementation of value-added control methods for the

total system. It provides a written summary description of the systems used in minimizing process and product

variation.

- All Special Characteristics (e.g., critical, key, significant, etc.) must be

ID'd/addressed on the CP - The CP is a living document that should be utilized/updated for the life

of the product.

- ANY CHANGES MADE TO THE PRODUCT CONTROL PLAN MUST HAVE "WRITTEN"

CUSTOMER APPROVAL. - The Control Plan MUST be signed/dated by the Supplier and the

Customer.

- In some cases VIA Motors will allow Family Group PFD's, FMEA's and Control Plan - When this is agreed


Page 23 of 48

upon, the supplier shall have a reference attachment for all part numbers and individual part

differences of the parts in the Family Grouping.

- The inspection frequency MUST be defined in quantifiable terms. ( i.e.- What is a "Lot"?)

FIRST ARTICLE

DIMENSIONAL LAYOUT

RESULTS

This record is used to verify the parts meet all of the dimensional requirements called out on the Drawing and Control Plan.

- If production parts will be produced from more than one component,

mold, tool, die, pattern, or production process, the supplier shall complete a dimensional

evaluation on a minimum of one part from each unique process/variation (Including color, if applicable,

for certain process')

The specific component, molds, line, etc. shall then be identified on the PSW & on the Dimensional

Results Report.

- All dimensions, characteristics and specifications noted on the Drawing and Control Plan should

be listed in a convenient/organized format with the actual results recorded.

- All records shall be submitted on the VIA Motors Dimensional Results Form.

MATERIAL, PERFORMANCE

TEST RESULTS

LAB &

FUNCTIONAL

RESULTS

This record is used to verify that the parts meet all of the Material and/or performance

requirements/specifications called out on the Drawing and Control Plan.


Page 24 of 48

- All dimensions, characteristics, and specifications noted on the Drawing and control plan should

be listed in a convenient/organized format with the actual results recorded.

- Material Testing Results, Performance Testing Results, and other engineering requirements on the

design record shall be less than one year old at the time of the initial submission. This data shall

be updated for engineering changes that affect the original data. The supplier shall also maintain

and update all testing data for each lot of material. When PPAP is requested for an engineering

change, the supplier shall submit the testing data that corresponds to the material for the change.

INITIAL PROCESS

STUDY

CAPABILITY

(CpK/PpK)

STUDIES

The purpose of this record is to determine if the production process will produce product that meets

the Customer's requirements.

- Suppliers must submit with their Cpk results at least 30 data results

that the Cpk results

The raw data (data points)

of the histogram (Graphs). - Supplier MUST submit Initial Process Study for all Special

Characteristics (e.g., critical, key,

The results significant, etc.) that are called out on the Drawing or Control Plan. Studies must be submitted that

(CPK, PPK, CP, etc.) are representative of each unique production process, e.g. duplicate assembly line and/or work

cell, each position of a multiple component die, mold, tool, or pattern, etc.

- The acceptance criteria for Capability Studies is as follows:

* SHORT TERM STUDY- MUST meet > or = to 1.67 Cpk

* LONG TERM STUDY- MUST meet > or = to 1.33 Cpk

- If CPK falls between 1.33 and 1.67 (Short Term Study), a corrective action plan and interim revised


Page 25 of 48

Control Plan (normally providing for 100% inspection) must be developed by the supplier and

approved by the customer prior to approval. New studies MUST be performed after corrective

action is implemented and must be included in a revised PPAP submission.

- ALL Initial Process Studies must be accompanied by Measurement System Analysis Studies.

- >>> Initial process studies must be performed for ALL engineering changes that could have an

effect on the Special Characteristics (e.g., critical, key, significant, etc.) that are called out on the

Drawing or Control Plan. If it is unclear please contact VIA Motors Engineering.

MEASUREMENT SYSTEM

ANALYSIS STUDIES

GAGE R&R,

BIAS,

LINEARITY, &

STABILITY

The purpose of this record is to verify that the Gage or measurement system is capable of accurately

assessing the quality of the parts.

- Measurement System Analysis Studies must be submitted with ALL

Initial Process Studies.

- Gage R&R, Bias, Linearity, & Stability must be submitted when

applicable.

Definitions: Please reference the Measurement Systems Analysis

manual.

Acceptance

Criteria:

Gage R&R- <10 is Acceptable, 10 to 20 may be Acceptable based on importance,

and >20 is Rejectable

Corrective action is necessary for all Rejectable

items.

- >>> Measurement System Analysis Studies must be included with all

Initial Process Studies for ALL engineering changes that could have an effect on the Special

Characteristics (e.g., critical,


Page 26 of 48

key, significant, etc.) that are called out on the Drawing or Control Plan. They must also be

submitted if the gage is modified for any reason. If it is unclear please contact VIA Motors Engineering.

- Attribute Studies (If Applicable) will be performed on 20 parts, with 2 operators

and 2 trials. To meet acceptance criteria all results from the study must "PASS".

DESIGN

RECORDS

DRAWINGS Suppliers MUST submit a ballooned copy of the drawing that

corresponds to the Dimensional, Material, and Performance

Results.

The drawing MUST be the official engineering released design

record.

The PPAP MUST meet ALL drawing requirements to be

considered for approval.

- When the design records, e.g. CAD/CAM math data, part drawings,

specifications, are in electronic format, e.g. math data, the supplier shall produce and submit a hard

copy (e.g. pictorial, GD&T sheets, drawing, specification pages, etc.) to identify measurements

taken.

LABORATORY SCOPE AND

ACCREDITATION

The purpose of this record is to verify that the supplier has used an Accredited Laboratory/Testing Facility

to perform all Material, Functional, and Performance testing called out on the Drawing and Control Plan.

- This Record must be submitted with ALL testing

data.

- This includes ALL standards and specifications called out on the Drawing and C.P.

- Records must be submitted by the Laboratory that actually performed the testing.

- Accreditation certification must NOT be out-dated.

- Testing facilities that are strictly Laboratory facilities by nature must submit Laboratory Scope


Page 27 of 48

and Accreditation because they are not able to acquire QS9000 Registration.

PROCESS FLOW

DIAGRAMS

PROCESS

FLOW

CHARTS

This record is used to verify that the supplier has thoroughly evaluated and analyzed the total manufacturing

or assembly process, from start to end, for all possible causes of variation (i.e. machines, materials, methods,

etc. ) and has organized the process in such a way as to eliminate/reduce the effect these variations will have

on the overall quality system.

- This document shall flow smoothly into the supplier Control Plan and

FMEA. Part/Process

Numbers and Process Name/Operation Descriptions should carry over and be consistent on all

three documents.

- Title blocks must be complete and must reference all, unique, VIA Motors information.

- Please use the standard VIA Motors Process Flow Diagram Forms or an approved AIAG Form.




PROCESS

FMEA

PROCESS -

POTENTIAL

FAILURE

MODE AND

EFFECTS

ANALYSIS


Page 28 of 48

To assure that all potential failure modes and the effects they have on a process have been considered

and eliminated/addressed. Please note the following:

- If there are no recommended actions you must state “none” in the

recommended actions column. - Do not use “Operator Error” as a potential failure. The failure is rooted

to a process or system. - A PFMEA should be created by a team which has representation from

every area of the process. - All Special Characteristics (e.g., critical, key, significant) must be

ID'd/addressed on the PFMEA. - Any issue, customer or internal, will require review/adjustment of

R.P.N. numbers.

- The PFMEA is a living document that should be utilized/updated for the life of the product.




DESIGN

FMEA

ONLY applicable when the supplier has design responsibility. A tool used when designing a component, system, process, etc. to assure, to

the extent possible,

that all potential failure modes (Design related) and their associated causes/mechanisms have been

considered and addressed. - Retain at supplier facility. Must be available for customer review at any

time.


Page 29 of 48

PPAP Submission Requirements &

Checklist

All documents must be submitted in VIA MOTORS accepted format

SUPPLIER

PART NUMBER

PART DESCRIPTION

PREPARED BY

REVISION DATE

SUBMISSION LEVEL (choose from drop down menu) Level 3

Submission Element Submission Requirement

Initial for

VIA Complian

ce

Approved Rejected Comments / Actions

NOTE: Regardless of the PPAP Submission Level, all the elements of a PPAP package must be completed. Only

those documents that are either marked "S" or requested by the SDE/SQA must be submitted to VIA. The entire

package is to be retained by the Supplier.

1. Design Record Print/Drawing or Specification

S

2. Engineering Change Notice Approved SRDC

S

3. Customer Engineering Approval

Approved VIA Motors signature on

supplier drawing

S

4. Design FMEA

For supplier designed part, if required

by VIA Motors

S

5. Process Flow Diagram Manufacturing process flow for part

S

6. Process FMEA Manufacturing analysis for product line

S

7. Control Plan Required for specific manufacturing plan of part

S

8. MSA Necessary when process capability is required

S


Page 30 of 48

9. Dimensional Results Record of inspection to print features

S

10. Material / Performance Result For specific test results or certification as instructed on print

S

11. Initial Process Study Required if classified characteristics are noted on print

S

12. Qualified Laboratory Documentation

As defined by VIA Motors

S

13. Appearance Approval Report

When required by VIA Motors

S

14. Sample Production Parts Production representative sample

S

15. Master Sample Retain for 30 days after PPAP Approval

R

16. Checking Aids Document special gauges or fixtures to validate sample

R

17. Record of Compliance

For VIA Motors specific requirements.

S

18. Part Submission Warrant

Approved VIA Motors version required

S

Checklist Issue and Receipt Sign-offs

Print Name Signature Date

Issued By: (VIA Motors SQE)

Supplier Receipt Confirmation and Agreement

Reviewed By:

(VIA Motors SQE)


Page 31 of 48

APPENDIX B: Initial parts production control sheet

INITIAL PARTS PRODUCTION

VIA MOTORS PART NAME:

PART NUMBER:

SUPPLIER NAME:

DESCRIPTION OF CHANGE:

DRAWING REVISION LEVEL:

DATE:

VIA MOTORS FACILITY:

VIA MOTORS MAT. HANDLERS: Default Location Incoming Inspection

REV 12/19/12


Page 32 of 48

APPENDIX C: Improvement report, NCR report, 8D form, guidelines for

rootcause analysis and checklist,

VIA MOTORS IMPROVEMENT REPORT

General Information

Improvement type: Corrective Action (low complexity and risk) Preventive Action Improvement

Improvement #:

Actionee: (include team members if applicable)

Effectiveness Auditor:

Describe the Situation

Situation Description: (Include reference to all applicable statistics, other reports, previous improvement reports, etc. Statement to include information about the current condition as well as the desired result from successful completion of this project. Attach documents as necessary)

Immediate Action/Containment Is containment action required? Yes No

If yes) Date Action is to be completed: Date Action was completed: Description of action taken:

Root Cause Analysis Describe the root cause of the Situation:

Improvement Action Action Definitions:

• Corrective action eliminates the cause(s) of a detected non-conformance (problem) and prevents its reoccurrence.

• Preventive action eliminates the cause(s) of a potential non-conformance (problem) and prevents its occurrence.

• Continuous improvement action increases system performance.

Date Action is to be completed: Date Action was completed: Description of action taken:

Effectiveness Audit

Estimated Date:

Actual Date:

Method of Effectiveness Evaluation:

Was the Initial Action Effective? Yes No


Page 33 of 48

VIA NON-CONFORMANCE REPORT

Date: MO/shipper: NCR №:

Incoming In-Process First Article

Final Customer Location

Part # and Rev: Serial Number: ____________________

Part Description: Vendor

Name:

____________________

Detailed/Purchased

Part/Component: VIA P.O. #: __________________

Customer/Program. Mgr: Initiated By: Nick Zielinski

Qty. Received: Qty. Rejected: Qty. Accepted:

NONCONFORMITY

Defect Description Recommendation

Finding: The 956-000024 vapor canister bracket is non-conforming.

Root cause analysis: to be determined by supplier:

Containment

Items on the floor: Items in stock: None Items shipped: None

MRB DISPOSITION

Customer Approval Required: YES NO

Use AS-IS: Qty: Return to Vendor: Qty:

Rework: Qty: Order Material: Qty:

Repair: Qty: Debit Vendor: Qty:

Scrap: Qty: Issue Credit: Qty:

Other: Improvement Report: #

Defect Code: # RMA: #

NCR Cost: $ 8D: #

MRB Disposition Comments:

Purchasing Engineering Operations Program Mgr Finance Quality

Approved by: Date:


Page 34 of 48

Vendor Notified by:

Date:

Disposition Completed By:

Date:


Page 35 of 48

Tracking Number: Customer Number: Response Due Date:

Actual Closing Date:

Status

8D @ VIA Supplier Corrective Action Form

850-01-02 Step 0 1 2 3 4 5 6 7 8

Action Prepare Team Describe Contain Diag. Solve Validate Prevent Wrap

Registered problem and Short

Term Corrective Action in

place in house.

Long Term Corrective Action

developed but not

implemented.


implemented.

Monitoring/evaluating

effectiveness.


confirmed effective. Problem

closed.

0

Prepare for Problem Solving - Does the problem warrant/require an 8D? If so comment

why and proceed.

Is an Emergency Response Action Needed?

(If needed document actions in Action Item Table)

1

Team Assembled - Establish a small group of people

with the process/product knowledge, allocated time, authority and skill in

the required technical disciplines to solve the problem and implement

corrective actions.

Team Goals:

Team Objectives:

Department Name (Team Leader First) Skills Responsibility

2A

Problem Description –

Sketch of Problem

Part Number(s):

Customer(s):

List all of the data and documents that might help you to define

the problem more exactly?

Is there an action plan to collect additional information?

Prepare Process Flow Diagram for problem. (Attach to PSW)


Page 36 of 48

2B IS IS NOT

Wh

o

Who is affected by the problem? Who first observed the problem? (internal/external)

To whom was the problem reported?

Who is not affected by the problem? Who did not find the problem?

Wh

at

What type of problem is it? What has the problem? What is happening? Do we have physical evidence of the problem in our possession?

What does not have the problem? What could be happening but is not? What could be the problem but is not?

Wh

y

Why is this a problem? Is the process where the problem occurred stable?

Why is it not a problem?

Wh

ere

Where was the problem observed? Where does the problem occur?

Where could the problem be located but is not? Where else could the problem be located but is not?

Wh

en

When was the problem first noticed? When has it been noticed since?

When could the problem have been noticed but was not?

Ho

w

Mu

ch

/

Ma

ny

Quantity of problem? How Much is the problem causing in dollars, people, & Time?

How many could have the problem but don’t? How big could the problem be but is not?

Ho

w

Oft

en

What is the trend (continuous, random, cyclical)? Has the problem occurred previously? (If so attach previous PSWs & CIFs)

What could the trend be but is not?

2C

Problem Description - Combine the relevant information, this will be your Problem

Description


Page 37 of 48

3

Interim Containment Actions - Temporary actions to contain the problem and “fix” until permanent correction is in place. (Note: Validate that the action taken works).

Document Actions in the Action Item Table

4A

Diagnose Root Cause – Analyze for “Root Cause” of the problem. Identify and verify the Escape Point.

Brainstorm the possible causes of the problem (attach)

4A Cause and Effect Diagram (Attach copy of complete diagram(s) as appropriate)

How made? Why did it get out?

People Materials/Info Machine Problem (effect) People Materials/Info Machine

Method Environment Measurement Method Environment Measurement

Note on Diagram(s) circle the most likely contributors (3 max) from each side.

4B 5 – Why Analysis

Ask – Why did this happen? Splicing occurred at HHI without request from VIA not notification to VIA.

Ask – Why did this happen?




4C Action Plan - Based on the team’s discussions. Begin to complete the Root Cause Action Plan to verify and

validate the root causes and test the escape point. Document this on the Action Item Table.

Find and Verify Root Causes Item Description PercentageContribution


Page 38 of 48

5 Identify Solutions – Solutions that address and correct the root cause. Solutions determined to be the best of all the alternatives. Document and verify the Permanent Corrective Action (PCA) in the Action Item Table.

Select Corrective Actions and Verify Ability to Prevent the Problem Item Action Description Responsible

Person

Expected Result Actual Result Effective?

(Yes or No)

6

Validation - Implement and validate to ensure that corrective action does “what it is supposed to do.” Detect any undesirable side effects. Document this on the Action Item Table. Return to root cause analysis, if

necessary.

Implement Permanent Corrective Actions and Validate Item Action Description Responsible

Person


(Yes or No)

7

Prevention (Design / Information Systems Review) - Determine what improvements in systems and processes would prevent problem from recurring. Ensure that corrective action remains in place and successful.

Actions to Prevent Recurrence of the Problem Item Action Description Responsible

Person


(Yes or No)


Page 39 of 48

7A Address Similar Systems - List similar systems with the potential for the same defect. Issue a CIF for

items identified.

Process / Item Accountability CIF #

7B Review the following documents / systems.

Document Accountability Completion Date

Planned Actual

Management System Manual

Manufacturing Work Instructions

Inspection Work Instructions

Flow Charts

Control Plans

Process FMEA Gauges/MMD/IMTE, Design FMEA,

PPAP

Engineering Change Approval

Manufacturing Forms

Inspection Forms

Others

Others

8 Congratulate Your Team - Use all forms of employee recognition and document as necessary.

Celebrate successful conclusion of the problem solving effort. Formally disengage the team and return to normal duties.

Was the PSW Effective?

Yes/No Signature/Title Date


Page 40 of 48

Doc #: 740-02-05 R1 04/11/13 VIA MOTORS Supplier Quality Manual 41

Action Item Table Actions Implement and Verify Actions

Action

#

Fault /

Item

Containm

ent/

Corrective

Action

Verify How

Verified Action

Accounta

bility Planned Actual

Stat

us

Registered problem and Short Term

Corrective Action in place in house.


developed but not implemented.

Long Term Corrective

Action implemented.

Monitoring/evaluating

effectiveness.

Long Term

Corrective Action

confirmed

effective.

Problem closed.

Note: Copy this page and attach as often as necessary

Appendix C, Attachment 2


GUIDELINES FOR ROOT CAUSE ANALYSIS

Use the Root Cause Analysis Worksheet to help determine root cause of problem. SECTION A: Problem Definition/Analysis (5W2H) Use 5W2H to provide as much information as possible. WHO - What part or item are you having a problem with? - Model and type; area affected. WHAT - What is wrong with it? - Symptom of problem; use illustrations to clarify. WHEN - When was the problem first found? - When since then has the problem recurred (is there a pattern forming)? - Date, time, etc. WHERE - Where on the part or car is the trouble located? - Where was the part or car located when you found the problem? - Location of occurrence; market, in-house. WHY - Why is it a problem? - Content of complaint. HOW - How was the problem found? - Visual inspection, customer’s complaint, etc. HOW MANY - How many parts or units have this problem? - Is the problem getting better, worse, or staying the same. Provide information about general condition of problem parts/processes:

− What related parts could also be having this problem, but for some reason are not at this time?

− What other problems could this part have, but right now, does not have?

− When else could this problem have been found?

− What other patterns could have been seen, but were not seen at this time?

− Is there any other place that the problem could be found on the part?

− Are there other places that could have reported this problem, but have not at this time?

− How else could it have been found, but was not?

− What percent of the parts or unit could have this trouble?

− What other types of trends could this have?

− Use illustrations to clarify the problem as much as possible.

SECTION B: Root Cause Analysis Tools 5 Whys

− Repeatedly ask yourself “Why” more than 5 times until you come up with a root cause for both hard and soft side. Hard side is to ask why the problem occurred. Soft side is to ask why the product was delivered to the next customer.


Cause and Effect Diagram

− Make sure that all possible causes have been identified.

− Use 4Ms (man, machine, method, material) and illustrations as necessary to prevent any from being left out.

− End causes (smallest bone) should be made clear to determine if concrete action can be taken.

− Write a “Problem Summary” encompassing original problem to smallest bone.

− Are causes in systematic order?

− Is there a relationship between the problem and the big, medium, small, and smallest bones?

− Make sure all causes are related to the problem.

− Are there causes included that are vague in meaning?

− Causes that came up through brainstorming can be interpreted in many different ways.

− Make sure that everyone has the same understanding of each cause.

− Identify causes having established standards from those without established standards.

− Prioritize causes for analysis and corrective action.

− Pick out key causes first and then work down toward minor ones.



ROOT CAUSE ANALYSIS WORKSHEET

A. PROBLEM DEFINITION/ANALYSIS (5W2H):

B. ROOT CAUSE ANALYSIS

OCCURRENCE (Hard Side) NONDETECTION (Soft Side)

1. Why:

1. Why:

2. Why:

2. Why:

3. Why:

3. Why:

4. Why:

4. Why:

5. Why:

5. Why:

ROOT CAUSE ANALYSIS DIAGRAM:



Supplier Quality Assurance Defect Corrective or Preventive Action (CAR, NCR or IR) Response/Evaluation Checklist

Part # ________Name __Date Supplier CAR, NCR or IR / MDPAR Number __________________

NOTE: All Sections shown in italics must be responded to with the initial response (i.e.

within 24 hours).

YES NA NO DOCUMENTATION RESPONSE EVALUATION

SECTION 1 – HEADER

1.1 The response is provided on VIA Motors form, concern number is present. All attachments submitted with the response must have the VIA Motors concern number referenced on them.

1.2 If the response is on the suppliers standard form, the VIA Motors “Concern Number” must be referenced / shown in the header information and all attachments, and at a minimum the supplier form must include all sections as shown on the VIA Motors form

NOTE: Supplier must respond with a “YES” to either Item 1.1 or Item 1.2 or the response will be

rejected.

1.3 The response identifies a champion leading the investigation, including the person’s name, job title and phone number.

1.4 All team members name(s) and job title(s) listed. NOTE: Based on the defect description, verify that the supplier is utilizing a cross-functional team approach.

SECTION 2 – CUSTOMER INITIAL DEFECT DETAILS

2.1 VIA Motors documented “CUSTOMER INITIAL DEFECT DETAILS” statement is shown on the form. This statement represents the VIA Motors initiators educated interpretation of the problem.

2.2 Supplier documented “EXPERT CONCERN DETAIL/PROBLEM STATEMENT” is shown on the form – supplier modified defect description to support their internal investigation.

SECTION 3 – SHORT TERM CONTAINMENT

3.1 Containment response issued by supplier and received by VIA Motors issuing division within 24 hours.

3.2 Containment activities / response to include, at a minimum:

REJ

a) Product in transit from the supplier or at VIA Motors Distribution Center, including “Hold / Reject” areas – may include product VIA Motors has already shipped or at the customer(s). Identify the date and whom the activity was assigned to. List quantity contained / suspect quantity found.

REJ

b) Product in process, being produced or in finished goods at the supplier, or stored at an off-site warehouse. Also, verify any product in a “Hold / Engineering” area that may contain the same defect. This investigation would also include any “family” parts that could contain the same problem (produced on the same process, but a different color, grade, configuration, etc.) Identify the date and whom the activity was assigned to. List quantity contained / suspect quantity found.

REJ

c) Product at, going to or returning from a sub-supplier. Identify the date and whom the activity was assigned to. List quantity of product contained / suspect quantity found.

NOTE: Additional minimum containment actions:

1) Certify all shipments until corrective action(s) have been implemented and verified to prevent the recurrence.

2) Green “X” (or obvious identifier that is clearly recognizable) identify all bar code labels

indicating that the product has been certified.

THE SUPPLIER MUST ADDRESS THE FOLLOWING CONCERNS IN

THEIR RESPONSE

REJ

3.3 For the appropriate containment activity (below), the supplier is to identify the verification method(s) to be used.

a) If 100% of all product reflects the concern, can an interim standard be implemented that does not

compromise the fit, form, function or appearance of the end assembly? Comment:

b) Can product be sorted / reworked? Comment:

1) If the product is to be reworked, the default verification will be to the Control Plan

2) If the product is to be sorted, the default verification will be to the specific failure

c) Can problem be immediately corrected to eliminate the issue for subsequent production? Comment::

d) Can a poke-yoke be implemented at the supplier / VIA Motors to prevent exposure to VIA Motors customer(s)? Comment:

e) Other? (Provide detail on specific containment activity.)



REJ

3.4 Using the “quantity contained / suspect quantity found” data from Section 3.2 – “a” through “c”, provide the actual Parts Per Million (PPM) calculation for each of the containment activities

NOTE: In Sections 3.2.a, b and c, and 3.4, for data that is not finalized for submission to meet the Initial Response deadline (24 hours), the supplier will respond with actual dates when the information will be forwarded to VIA Motors.

SECTION 4 – ROOT CAUSE(S)

NOTE: Root cause must address the “Customer Initial Defect Details” and the “Expert Concern Details / Problem Statement” identified on the CAR, NCR or IR (see Section #2).

4.1 Potential Root Cause(s) – Initial evaluation of the source point or system root cause that contributed to the failure must be included with the initial response. The initial analysis will identify numerous potential root causes through the application of the basic problem solving tools (5 whys/Cause & Effect/Is – Is Not/ Etc.) NOTE: With the initial 24-hour submission, the supplier is to list all potential root causes in the “Primary Root Cause” section. This field will also be used for the final response root cause.

4.2 Root Cause(s) – The result will be the identification of the true root cause(s). This could result in several core documented responses.

REJ

a) Supplier details a fact based response to the “CUSTOMER INITIAL DEFECT DETAILS” and/or “EXPERT CONCERN DETAILS / PROBLEM STATEMENT”

REJ

1) Primary Root Cause : Point of failure process or design root cause. Enter the “date” this root cause(s) was determined, and “who” is responsible to ensure all root cause analysis activities are completed.

REJ

2) Secondary Root Cause: Identify what allowed the defect to be shipped. Enter the “date” this root cause(s) was determined, and “who” is responsible to ensure all root cause analysis activities are completed.

3) Document the details of the specific quality system element (identified in the Header information). Input this response in the “Secondary Root Cause” field. Enter the “date” this activity occurred and “who” ensured this activity was completed

4) The documented ability to turn the problem off and on again. Input this response in the “Secondary Root Cause” field. Enter the “date” this activity occurred and “who” ensured this activity was completed

4.3 For “Warranty Concerns”, supplier is to enter “NO” unless directed by the issuing VIA Motors representative.

SECTION 5 – MISTAKE PROOFING

REJ

5.1 Provide a list of “mistake proofing” options that were considered based on the identified

product non-conformance. For those not implemented, provide the rationale on why they were not

pursued.

SECTION 6 – CORRECTIVE ACTION

REJ

6.1 The correct response must have a documented corrective action plan for all identified actual root causes shown in the previous steps. NOTE: The corrective action(s) must eliminate the root cause(s).

6.2 The corrective action must address the condition(s) that resulted in the failure, including:

REJ

a) Primary root cause point of failure - process or design

REJ

b) Secondary root cause failure to contain the defect

REJ

6.3 The corrective action(s) must identify date(s) when permanent actions are 100% implemented.

SECTION 7 – VERIFY EFFECTIVENESS

REJ

7.1 The correct response must identify the documented form or method of verification, who is responsible, the due date and actual dates completed.

7.2 The verification of effectiveness shall include data gathered to validate the problem resolution and corrective action(s). The data to be submitted should include proofs such as X-Bar and R Charts, Cpk analysis, P-Charts, Inspection Reports, etc.

7.3 The data to be submitted shall include a significant time period to be agreed to by VIA Motors SQA (dependent of frequency / duration of production runs) ,with evidence that the issue has not occurred again.



NOTE: Based on the successful verification, VIA Motors SQA will advise supplier on discontinuation of containment and certification.

SECTION 8 – PREVENT RECURRENCE

REJ

8.1 The correct response will identify the documents that are (will be) updated, the person(s) responsible, the due date(s) and the actual completion date(s).

8.2 Response may include updates of the system documents to support the institutionalization of the corrective actions. Documents to be updated include, but not limited to:

a) Potential Failure Mode and Effects Analysis (PFMEA)

b) Control Plan

c) Process Flow Diagram

d) Work / Operator Instructions

e) Quality System Procedures

REJ

8.3 Global Effectiveness: Supplier repeats this activity on common parts / processes and sister plants to prevent similar failures from occurring. Submit detailed information on common VIA Motors parts and actions to be taken. If it is identified that common parts / processes are to be excluded from this activity, please provide the rationale for exclusion.

SECTION 9 – INITIAL / LONG TERM VERIFICATION

REJ

9.1 Initial verification – Provide documented evidence (from a person independent of the team that investigated the problem) that there was an audit of the CAR, NCR or IR/MDPAR, and the actual system is consistent with the documented response.

9.2 30 / 60 / 90 DAY VERIFICATION – Based on VIA Motors direction, the supplier will be notified if additional verification is required, and the means on how that verification is accomplished and communicated. This activity may be requested on “CC” DCARs but is recommended for all VIA Motors CAR, NCR or IRs.

Rev 12/19/12


APPENDIX D Supplier Pre-selection and Performance Rating System

Appendix D

Supplier Selection and Performance Rating System Introduction

VIA Motors intends to establish and maintain long-term relationships with suppliers who are committed to

continuous improvement in quality, cost, delivery and service. This commitment is an expectation of all

suppliers who participate in the automotive industry. Those suppliers who embrace this philosophy will have

the opportunity to enter into long-term agreements with VIA Motors. We believe evidence of this

commitment to a continuous improvement philosophy includes; TS16949, and/or ISO-9000 certification,

proactive supply-chain management, daily or multi-day deliveries, productivity improvements and frequent

cost-savings proposals. In turn, VIA Motors will deal honestly with our suppliers, strive to listen to our

suppliers concerns, communicate our requirements and provide our suppliers with the appropriate tools to

perform at world-class levels.

Purpose

The VIA Motors Supplier Performance Rating System (SPRS) is a means to help communicate our

expectations to the supply base. Suppliers are expected to use these results to help identify opportunities for

continuous improvement in the areas of quality, cost, delivery and service. Internally, these measures provide

valuable data to assist VIA Motors Purchasing in sourcing decisions.

Scope

The scope includes production suppliers to all VIA Motors production facilities.

Tool

VIA will audit it suppliers using a Vendor Survey (separate Word File) which is sent to all potential VIA

suppliers as well as a detailed Supplier Assessment Questionnaire which will be validated during an Initial

Supplier Qualification Process and visit as well as periodic reviews and visits of the suppliers manufacturing

sites.

The supplier evaluation is based on the review of Purchasing, Technology, Logistics, Quality and PPAP

areas. The suppliers will be scored based on the Performance in each of these areas. Results will be discuss

with suppliers and corrective actions will be requested where deemed necessary.