Pso 6.0 PDF

Advance Quality Planning &
th
Process Sign-Off 6 Edition
AQP
PSO
COPYRIGHT 2009 CHRYSLER LLC
ADVANCE QUALITY
PLANNING &
PROCESS SIGN-OFF (PSO)
6th Edition
January 2009
INTENTIONALLY LEFT BLANK
Advance Quality Planning &

Process Sign-Off (PSO)
FOREWARD TO THE 6th EDITION
This manual defines the requirements for Advance Quality Planning (AQP) and Process
Sign-Off (PSO), required to verify conformance to Chryslers Quality System Standards.
AQP, PSO, ISO/TS-16949 and the Chrysler Development System (CDS) form the
foundation for Supplier readiness to ensure a successful program launch. A Suppliers
certification to ISO/TS-16949 alone is not sufficient for PSO approval; all PSO requirements
must be met to assure conformance to dimensional, material, functional and, where
applicable, appearance requirements. In addition, every external Supplier of production
parts to Chrysler shall be ISO/TS-16949:2002 third party registered. Effective January
5th, 2009, the requirements stated in this document apply to all Chrysler Production
Suppliers, including sub-tier Suppliers.
In order to achieve part quality improvements, this manual has been modified to reflect
Chryslers current AQP and PSO philosophy. Emphasis was placed upon adherence to
the Chrysler Development System (CDS). In addition, the Supplier Quality Assurance
Process (SQAP) 3rd Edition Manual, formerly used within the NEA market, has been
incorporated into the PSO process. Review this manual carefully and in its entirety to
assure that all PSO requirements are known and understood.
The name Chrysler, as used in this manual, refers to Chrysler LLC and its subsidiaries
which manufacture Chrysler, Dodge and Jeep brand vehicles. The word Supplier is
intended to indicate both external and internal Tier 1 Suppliers. The term sub-tier
Suppliers refers to all Tier 2 and lower organizations, both internal and external.
Chrysler PSO Team denotes Chrysler Employee involvement only, while PSO team
indicates all individuals involved in the PSO process (i.e., Chrysler and Suppliers).
The term Chrysler Supplier Quality Engineer or SQE, as used in this manual, refers to
the Chrysler LLC Supplier Quality Engineer.
The term shall, as used in this manual, indicates mandatory requirements. The word
should indicates a suggestion or recommendation. Suppliers choosing other approaches
shall be able to show that their approach meets the intent of this manual.
For questions or comments concerning the Process Sign-Off manual, please contact your
Chrysler Supplier Quality Engineer (SQE).
ACKNOWLEDGMENTS
ADVANCE QUALITY PLANNING &

6th Edition
AQP & PSO 6th Ed. Team Members
David Eller
Manager Supplier Quality Processes & Training
Bryan Book
Supplier Quality Processes & Training
Vic Randolph
Rich Merna
Inbo Kim
Sr. Manager CoC International Supplier Quality
Jim Gajda
Manager International Quality
Jinghua Rong
Manager Supplier Quality (NEA)
Chris Hegele
Supplier Quality - Exterior
John Che
Supplier Quality - Electrical
Rick Lewis
Supplier Quality Body-In-White
Larry DAgostino
Supplier Quality Chassis
Mike Carr
Supplier Quality Chassis
Greg Masel
Supplier Quality - Interior
Mariana Luna
Supplier Quality Powertrain
Lisa Sacino
Corporate Quality
Jose Velez
Powertrain Manufacturing Quality
Lynn Yang
Powertrain Quality
Ed Myzienski
FMEA CoC
Requests for revisions or changes to the manual

should be directed to the Supplier Quality
Operations group
ADVANCE QUALITY PLANNING &

Table of Contents
Page
Advance Quality Planning......................................................................................... 1
Process Sign-Off ...................................................................................................... 4
Process Sign-Off Element Requirements.................................................................. 11
Appendix A Forms and Instructions ......................................................................... 49
Appendix B Tables and Examples ........................................................................... 69
Appendix C FTC Calculations .................................................................................. 75
Appendix D PSO Extended Run ............................................................................... 81
Appendix E Forever Requirements ........................................................................... 83
Appendix F Internal PSO Requirements .................................................................... 89
Frequently Asked Questions .................................................................................... 95
Reference Manuals............................................................................................... 100
Glossary .............................................................................................................. 101
Index................................................................................................................... 113
Advance Quality Planning (AQP)

PURPOSE: Advance Quality Planning (AQP) details the tasks performed by the Supplier
and Chrysler that ensure parts which meet all requirements are delivered on time to
designated manufacturing facilities.
PROCESS INPUTS: Those items necessary in order to begin the AQP process include:
New or modified component or module with the Supplier identified
Source package
Engineering specifications and design model
Chrysler Development System (CDS) timing and gate requirements
Engineering Change Notices (CNs), if applicable
Lessons Learned from previous programs
PROCESS OUTPUTS: Completion of the AQP process results in:
Process Sign-Off (PSO) A Approval
Appearance Approval
Production Part Approval Process (PPAP) A disposition and Part Submission
Warrant (PSW) completion
DESCRIPTION: The AQP process begins when the Supplier is identified for a new or
modified part and the part is assigned to the appropriate Chrysler Supplier Quality
Engineer (SQE). The SQE leads the AQP Team, which also includes the Chrysler Engineer
and Supplier personnel (including the Program Manager, Engineering, and Quality
functions at a minimum). Other supporting Chrysler personnel are included as needed
(e.g. the Buyer, Product Team SQE (PTSQE), Logistics, Material Handling Engineering
(MHE), and Advance Manufacturing Engineering (AME)).
The SQE and Supplier are responsible for ensuring that required quality gate deliverables
are complete and acceptable by their due dates. Reference the Chrysler Quality
Management System (CQMS) Part Information screen, the "CDS Quality Gate Timing"
report in the Advanced Quality Information System (AQIS), and the CDS website for
timing for all deliverables. Deliverables that are considered Risk to Launch (see below),
or are late for their quality gate, should have a Recovery Plan documented in the
Executive Summary form and implemented by the AQP team, as necessary.
Key Components
The Product Team SQE (PTSQE) is responsible for designating Key components by
quality gate G1 Theme Selection. Reference the Chrysler process Key and Risk to
Launch Component Designation for Supplier Quality in the Global Sourcing Book of
Knowledge (BoK) for full details.
NOTE: Suppliers do not have access to the Chrysler BoK and should contact their SQE
for information on any process in that system.
Initial Risk Evaluation (IRE)
An IRE is required on all new or modified parts or modules within 14 days of Supplier
selection. SQEs can reference the process Completing an Initial Risk Evaluation (IRE) in
the BoK for details on submitting an IRE into the appropriate Chrysler system.
Chrysler involvement in AQP and PSO is based upon the IRE, as follows:
For parts assigned a High Risk Level, the SQE leads both the AQP and PSO.
For parts assigned a Medium Risk Level, the Supplier leads the AQP and the SQE
leads the PSO.
For parts assigned a Low Risk Level, the Supplier leads both the AQP and PSO.
NOTE: For programs with Supplier-led AQP, the Supplier may use either the AQP
process or the AIAG Advanced Product Quality Planning (APQP) and Control Plan
manual. See Chryslers Customer-Specific Requirements for ISO/TS-16949, cl. 4.2.2.
The following Risk Drivers should be reviewed in order to determine the risk level of the
component or module when performing the IRE:
Are there issues preventing Primary Production Tools Complete by S1 Start?
Will PPAP be completed by S2 Start Readiness?
Is the design complete?
Has Historical Design Stability (e.g., high CN activity) been considered?
What is the Customer impact if the part fails (Safety, appearance, function, etc.)?
What is the level of process technology (e.g., established, widespread, innovative)?
Is this a new manufacturing location?
Have there been historical quality problems with similar parts?
Is the Supplier ISO/TS-16949 certified?
Is the Supplier PPAP Self-Certified?
What is the Suppliers EBSC measure for quality?
Has the Supplier historically required multiple PSO visits to obtain PSO approval?
Has the Supplier recently been placed on 3CPR?
What is the Suppliers ability to successfully conduct AQP/APQP activities?
AQP Meetings
AQP Meetings are required for all High-risk components and modules, and should be held
on a regular schedule as determined by the AQP Team (suggested weekly). Meetings for
Medium-risk components and modules can be held on an as needed basis, as
determined by the SQE and/or Engineer. The SQE schedules the meetings, acts as chair,
and is responsible for their proper documentation (but can delegate this task as
necessary). Some meetings should be held at the Supplier and Chrysler (or Chryslerdesignated) manufacturing facilities, if possible.
The initial kick-off AQP meeting should be held at the beginning of the program, after
completion of the IRE. Kick-off AQP meeting suggested activities include:
Review the IRE
Establish team roles and responsibilities
Determine AQP meeting frequency
Confirm core AQP Team members
Review the source package
Review volume assumptions (e.g., shift pattern agreement with P.O. volumes)
Establish and review program timing/major milestones/CDS gate timing
Establish AQP/Process Sign-Off (PSO) expectations
Confirm manufacturing location
When initial program timing is developed, deliverables for quality gates that are already
past due shall be included for completion. These deliverables shall be distributed into
appropriate, future quality gates as determined by the AQP Team.
AQP meetings should include review of the following activities:
Program timing and major milestones
CDS timing and gate deliverables for the current and next quality gate
Open issues
NOTE: The SQE is responsible for open issues tracking, but may delegate this task as
necessary.
To assist with planning, tracking, and reporting deliverables and issues during AQP, the
following documents and forms are available: the Executive Summary form, AQP Open
Issues form, and AQP Timing chart. The Executive Summary and AQP Open Issues
forms are required for all High-risk parts and strongly recommended for all other parts.
See the PSO website https://gsp.extra.chrysler.com/qlty/pso/index.html and Appendix A
for electronic and hard copy versions.
Risk to Launch parts
The PTSQE may designate any part to be a Risk to Launch at any stage of the program.
Reference the Chrysler process Key and Risk to Launch Component Designation for
Supplier Quality in the Global Sourcing Book of Knowledge (BoK) for full details.
First Production Shipment Certification (FPSC)
The First Production Shipment Certification (FPSC) process must be initiated by the
Supplier prior to Gate C - S1 Start. See "First Production Shipment Certification" in the
BoK and PSO website (https://gsp.extra.chrysler.com/qlty/pso/index.html).
PSO is the verification that AQP has been successfully completed. PSO is detailed more
fully in the following section.
Production Part Approval Process (PPAP)
Upon receipt of PSO A Approval, the Supplier can proceed with their PPAP submission
in the Chrysler Quality Management System (CQMS). PSO A Approval and PPAP
submission is required prior to supplying parts for Gate S2 Start Readiness. An Interim
Approval Authorization (IAA) may be required for parts that have not completed PPAP
before they can be shipped to the Chrysler (or Chrysler-designated) facility. Suppliers
should contact their Chrysler SQE or Product Engineer for additional information
regarding IAAs. For full PPAP details, refer to the Production Part Approval Process
(PPAP) manual from the AIAG and the Chrysler Customer-Specific Requirements for PPAP
at http://qmsi.extra.chrysler.com/wi/clients/QMSI_e.
NOTE: PSO Z Approval, along with a dimensional PPAP submission, is insufficient to
allow a Supplier to ship parts to Chrysler; an IAA is required.
Forever Requirements
Proposed changes to the manufacturing process after PPAP must be requested through
the WebCN/FR system prior to implementation. See Appendix E in this manual.

PURPOSE: PSO is a formal review of the Supplier's production manufacturing process. It
is the culmination of Advance Quality Planning (AQP) and verifies a Suppliers ability to
manufacture production material that meets all Chrysler requirements at the Daily Tool
Capacity as noted on the Production Purchase Order (P.O.).
Process Sign-Off (PSO) shall be performed on all new or modified components with PPAP
requirements or components that have been out of production for 12 months or longer.
Additional conditions that may require a PSO include, but are not limited to:
Carry-over parts with historical quality problems and/or high warranty
Carry-over parts which have experienced a Supplier-responsible yard hold within
the past calendar year
New and/or additional production lines (e.g. capacity increases)
Production line moves
Any product or process change occurring during the lifecycle of a part or system
Any other component that the SQE determines requires one
Full compliance with all PSO requirements ensures that the Suppliers manufacturing
process is stable, in control, and capable of producing parts that meet all requirements.
PROCESS INPUTS: The following deliverables must be completed prior to beginning the
PSO process:
Primary production tooling (prior to Gate C S1 Start)
Equipment, fixtures, and gages (prior to Gate C S1 Start)
Initial station cycle time and First Time Capability (FTC) compliant (prior to Gate C
S1 Start; may be combined with the Supplier Readiness Evaluation; see below)
PSO documentation (completed during the previous AQP stages)
PROCESS OUTPUTS: PSO A Approval, which allows the Supplier to complete the PPAP.
DESCRIPTION: PSO is a formal review of the Supplier's production manufacturing
process. It includes evaluation of associated production facilities, related manpower,
equipment, material, methods, procedures, software level(s), and tooling. The PSO
examines the Suppliers entire production process, including in-house and secondary
systems that support primary production line(s). It may include visits and/or reviews of
sub-tier Suppliers processes, at the discretion of the Chrysler PSO Team.
The PSO Team consists of, at a minimum, the Chrysler SQE, Chrysler Product Engineer
and Supplier(s) Representatives. Other Chrysler PSO team members may include, but
are not limited to: the Buyer, Center of Competence (COC) Engineer, and PTSQE. The
Supplier shall identify Supplier PSO team members for both Chrysler-led PSOs and
Supplier-led PSOs. For Supplier-led PSOs, Chrysler team members are not required to
participate, but shall if deemed necessary.
The Chrysler SQE leads the PSO for components with Medium and High risk levels.
The Supplier leads the PSO for components with a Low risk level.
The PSO process is comprised of four activities: the Supplier Readiness Evaluation (SRE),
the Pre-PSO Meeting, the PSO On-Site Visit, and Production Validation (PV) Testing.
Supplier Readiness Evaluation (SRE)

The Supplier performs the SRE prior to the Pre-PSO Meeting. The SRE consists of at least
one trial run to evaluate the Suppliers readiness for the PSO On-Site Visit. In order to
run the SRE, the following must be complete:
Primary production tooling
All equipment, fixtures, and gages used in the production process
The quantity of parts to be run (determined by the Supplier, with Chrysler PSO
Team concurrence).
NOTE: Station cycle time and FTC compliance activities may be combined with the
SRE if performed prior to Gate C S1 Start. If the SRE cannot be run prior to Gate C
S1 Start, station cycle time and FTC are done separately.
Results from the SRE are recorded on the Supplier Readiness Evaluation/Trial Run
Results form (located in Appendix A and on the PSO website).
For full SRE requirements, see Element 15 in this manual.
Pre-PSO Meeting
The Chrysler SQE will schedule and coordinate the Pre-PSO Meeting with the Supplier
and Chrysler Engineer after the SRE has been completed.
The following activities should take place during the Pre-PSO Meeting:
Review of all documentation required for the PSO
Review of SRE results
Review of expectations and agenda of the PSO On-Site Visit, including PSO
Extended Run requirements, if applicable (see Appendix D)
Scheduling of the PSO On-Site Visit (if all previous items are acceptable)
The PSO Team should only schedule the PSO On-Site Visit when they agree that:
All required Supplier documentation has been reviewed and is acceptable
The SRE is complete and the results have been documented and are acceptable to
the team, including station cycle time and FTC
Production operators are trained and capable of running at the required line speed
PSO On-Site Visit
The PSO On-Site Visit consists of the formal review of the Suppliers facility and
processes, including the Production Demonstration Run (PDR). The purpose of the PDR
is to demonstrate Supplier process capability and production capacity. The PDR shall
produce dimensionally correct parts on the production line with production tooling.
The PSO team shall witness at least one PDR during the PSO On-Site Visit using
completed production tools. Production process review and measurements will provide the
production line rate, the final evaluation of FTC, and other statistics that validate the
Suppliers ability to effectively produce a part which meets all customer requirements.
The PSO Team shall complete the first 20 elements of the PSO Summary Report at the
Suppliers manufacturing facility during the PSO On-Site Visit. All portions of the
Suppliers process shall be reviewed, including those outside of the PDR (e.g. Shipping &
Receiving, Preventive Maintenance, Testing Facilities, etc.).
Production Validation (PV) Testing

Production Validation (PV) Testing validates the Suppliers process and provides evidence
that the parts meet engineering, quality, durability, and reliability requirements contained
in the Performance, Process, and Material Specifications. Component-level PV testing
shall be completed by Gate C S1 Start.
PV Testing shall be conducted on parts from the SRE or equivalent trial run that meet the
following requirements:
All process performance index (PP and PPK) requirements are met, or 100%
dimensionally inspected.
The SRE/trial run met the required station cycle time and FTC.
All sub-components and materials used in the SRE/trial run had an approved PPAP
(or equivalent).
Production processes and tooling were used.
All gages and testing equipment have acceptable R&R results.
Packaging and shipping or simulation test approvals are required by Material Handling
Engineering, if applicable. However, PSO approval shall not be delayed due to a lack of
approval(s) for Chrysler-provided and/or designed packaging (see element 17).
PSO Approvals
The Chrysler SQE is responsible for assigning the PSO approval level for Medium and
High risk parts. The Supplier is responsible for Low risk parts.
PSO N Approval: N Approval indicates that one or more PSO Elements is unapproved
and corrective action is required by the Supplier. A new PSO On-Site Visit (including
PDR) may be required, as determined by the Chrysler PSO Team. PV Testing may be
delayed or repeated at the discretion of the Chrysler PSO Team.
PSO Z Approval: Z Approval indicates that the first 20 PSO elements have been
completed and approved. It authorizes the Supplier to submit a dimensional PPAP in
CQMS, making them eligible for partial tooling payment (contact the Chrysler Buyer for
details).
PSO A Approval: PSO A Approval confirms that all PSO requirements have been met
by the Supplier. The Supplier may submit both dimensional and material PPAP in CQMS,
and is eligible for full tooling payment.
Deviations from the PSO requirements in this manual (including Mandatory
English document requirements, changes, omissions, and/or additions) shall be
requested and approved in writing by the Chrysler SQE and Product Engineer,
regardless of risk level. Approval(s) shall be obtained from Chrysler before
completion of the PSO process. Requested deviations shall be detailed within the
PSO Comments Sheet.
Advance Quality Planning Flowchart

1) Identify "Key"
components
2) Determine New/
Modified Parts.
3) Review IRE "Risk

Drivers" and assign
Risk Level (H/M/L)
New/Modified part Risk Level
Low
Medium
4a) Supplier leads the

AQP and PSO
4b) Supplier leads the

AQP and Chrysler
leads the PSO.
High
4c) Chrysler leads
both the AQP and
PSO.
5b) AQP begins. Conduct

regular AQP Meetings. Use
Executive Summary, AQP
Timing, and AQP Open Issues
forms to track deliverables and
open issues.
5a) Quality planning phase

begins. Use Chrysler AQP
forms and process or APQP
process, as applicable.
6) Identify "Risk to
Launch" parts (may be
done at any program
stage). Develop
Recovery Plans, as
necessary
7) Begin FPSC
process prior to Gate C
- S1 Start.
8) Schedule, determine
quantity, and perform
Trial runs / SRE.
9) PV Testing
10) Schedule and

perform Pre-PSO
Meeting. Review SRE
data and other required
information.
11) Conduct PSO OnSite Visit (including

PDR).
PSO On-Site Visit Result
"N" Approval
"Z" Approval
"A" Approval
12a) Resolve PSO

Open Issues.
Reschedule On-Site
Vist, if required.
12b) Submit full PSW/

PPAP
14) Changes to the

part or process after
PPAP approval require
submission via the
WebCN/FR system.
Repeat AQP process.
12c) Submit
dimensional PSW/
PPAP
13) Complete PSO

Element 21
End AQP Process
RESPONSIBILITY
LEGEND
L = LEAD
RESPONSIBILITY
S = SUPPORT
L/S = DEPENDS ON
PART RISK LEVEL
STEP
Identify Key
1
Components
Determine
2
New/Modified Parts
IRE & resultant risk
3
level
4a Supplier-led AQP & PSO
Supplier-led AQP,
Chrysler-led PSO
4c Chrysler-led AQP & PSO
Quality Planning phase
5a
(APQP)
5b AQP phase
Identify Risk to
6
Launch Parts
4b
REMARK
Low risk
Medium risk
High risk
Low & Medium

risk
High risk
S
S
At any program
stage
Prior to Gate C
S1 Start
FPSC
8
9
Trial Runs/SRE
PV Testing
S
S
S
S
L
L
10 Pre-PSO Meeting
L/S
L/S
11 PSO On-Site Visit
L/S
L/S
PSO Visit Result
L/S
L/S
Low: Supplier
Med/High: SQE
N Approval
A Approval
Z Approval
Corrective Actions,
reschedule PSO On-Site
12b Submit full PPAP
Submit dimensional
12c
PPAP
12a
13 Complete Element 21
14
SUPPLIER
CHRYSLER
SQE
CHRYSLER
ENGINEERING
CHRYSLER
PRODUCT TEAM SQE
ADVANCE QUALITY PLANNING

FLOWCHART RESPONSIBILITIES
submissions
Via WebCN/FR
10
PSO ELEMENT REQUIREMENTS
11
ELEMENT 1 - ADVANCE QUALITY PLANNING (AQP)

Element Requirements
Documentation
1.1 All new or modified components or modules must have an Initial
AQP forms, as required
Risk Evaluation (IRE) performed by the Chrysler SQE. Those
(Process Schedule,
components assigned a High risk are required to follow the AQP
Timing chart, Gate
process detailed in this manual.
Requirements and
Tasks, Executive
NOTE: The Chrysler AQP process is also recommended for all
Summary)
components or modules given a Medium or Low risk. Suppliers
Supply Chain diagram
may use an equivalent Advance Product Quality Plan (APQP) process,
Listed risk of all subif desired. All plans shall coordinate with the Chrysler Development
components and subSystem (CDS) timing for each applicable program and identify major
tier Supplier
milestones, required product or process deliverables, responsible
processes.
organizations, and promised and actual timing dates. Reference the
PSO/PPAP
Advanced Product Quality Planning (APQP) and Control Plan manual
documentation for all
and CDS at http://roadmap.tcc.chrysler.com/cds/.
sub-components and
sub-tier processes
1.1.1 The Supplier shall prepare and update after each AQP
risked medium or
meeting an AQP Timing chart and, if directed by the SQE, an
high.
Executive Summary and AQP Open Issues form for each
component or module following the Chrysler AQP process. The
forms shall be prepared and updated for all other components
upon request of the SQE.
1.1.2 Supplier contact information on the Executive Summary
form must include, at a minimum, the primary contacts for the
following (at a minimum): program management, quality issues,
launch support, and warranty issues. The same name may be the
contact for more than one of the preceding; however, there must be
at least two different contacts listed. Other contact names shall be
provided by the Supplier upon request.
1.1.2.1 The Supplier shall provide both a Plant and Warranty
Quality Representative, as required, to assist Chrysler
personnel throughout the life of the program.
1.1.2.2 When the Supplier is a Chrysler directed sub-tier, the
Supplier Representative(s) shall support the Tier 1 in the same
manner as they would Chrysler. Support is to begin at Gate G1
Theme Selection and continue through the life of the program.
Sub-tier Supplier
quality performance
process
Sub-tier Supplier
Forever
Requirements
conformance
verification
Corrective Action
procedure
DOE (Design of
Experiments) process
or equivalent
eCIMS or 8-Step
Corrective Actions for
issues encountered todate
Lessons Learned
Communication
procedure
Supply Base Management

1.2 The Supplier shall cascade AQP/APQP requirements throughout
all sub-tier Suppliers (see ISO/TS-16949 cl.7.4.3). The Tier 1 Supplier
is responsible for the quality of their sub-tier Suppliers.
1.2.1 The Supplier shall prepare a Supply Chain diagram. This
diagram shall outline the entire Supply Chain, beginning with raw
materials and ending with the Chrysler or the Chrysler-designated
manufacturing facility. All secondary processes and/or services
(e.g. plating, heat treating, etc.) shall be shown, including off-site
storage or shipping locations.
12
ELEMENT 1 - ADVANCE QUALITY PLANNING (AQP), CONT.

1.2.2 Each sub-component listed on the Bill of Material (BOM)
corresponding to the Chrysler part number shall have an IRE (or
equivalent) performed by the Supplier. The criteria for risking
components shall take into consideration the Chrysler risk drivers.
1.2.2.1 Each sub-component determined to be medium or
high risk (or equivalent) shall be accompanied by a PSO (or
equivalent process) conducted by the Tier 1 Supplier. Level 3
PPAP documentation is also required for sub-components.
Additional documentation may be requested by the Chrysler
SQE. See the AIAG Production Part Approval Process (PPAP)
manual for details.
1.2.3 The Supplier shall have a process which monitors and
documents the quality of all sub-tier Suppliers. This process shall
include a list of sub-tier Suppliers rated acceptable by the
Supplier and the criteria used to determine acceptability.
1.2.4 The Supplier shall have a process to cascade Chryslers
Forever Requirements to all sub-tier Suppliers. This process shall
include a method of verifying sub-tier Supplier knowledge and
conformance to the Forever Requirements. See Appendix E for
additional information.
NOTE: Suppliers with consigned Tier 2 Suppliers, and some directed
Tier 2 Suppliers, may be exempt from the requirements listed above in
1.2 through 1.2.4, for those Tier 2 Suppliers only. Contact your
Chrysler Buyer and SQE for information.
Problem Solving
1.3 The Supplier shall have a procedure to convey lessons learned and
corrective actions throughout their facility and all other facilities
within the same company. Reference ISO/TS-16949, cl. 8.5.2.1.
1.3.1 Corrective action shall be implemented across
the entire manufacturing plant for every applicable Chrysler
production line.
1.3.2 The procedure shall ensure the communication of lessons
learned, best practices, and known systemic weaknesses across
all facilities, and track the progress of implementation.
1.4 The acceptable methods for documenting root cause analyses and
corrective actions are through the Chrysler e-CIMS system and/or the
8-Step Corrective Action form.
1.5 The PSO team shall review corrective actions for any nonconformances or test failures encountered prior to the PSO visit (e.g.
during pilot builds, DV testing, etc.). The team shall ensure that all
corrective actions have been completed and implemented.
13
ELEMENT 1 - ADVANCE QUALITY PLANNING (AQP), CONT.

1.6 The Supplier shall have a procedure for conducting Design of
Experiments (DOE) or equivalent activities. DOE shall be conducted to
identify and establish the optimal process parameters for all new and
modified parts prior to the PSO On-Site Visit.
1.7 The Supplier shall support all Chrysler systems (e.g. eCIMS, NonConformance Tracking (NCT) system, CQMS, PRAS, COVISINT, etc.).
1.7.1 The Supplier shall have at least 2 individuals with valid SIDs
and passwords for each applicable Chrysler system (e.g. NonConformance Tracking, eCIMS, COVISINT, PRAS, etc.). All
individuals shall be fully trained in the use of each system for
which they access, and at least one of the trained individuals shall
reside at the Suppliers manufacturing facility. Contact
information shall be kept current and updated regularly.
1.8 Design responsible Suppliers are shall consider Design for
Serviceability, which ensures ease of disassembly of product with
minimal cost and time.
14
ELEMENT 2 - PART NUMBER, DESCRIPTION AND CHANGE LEVEL

Documentation
2.1 The PSO team shall review all PSO related documents to ensure
CATIA files, drawings,
correct part number, description and change level present, or are
Comment page, Part
cross-referenced (see ISO/TS-16949 cl. 4.2.3).
Information Pages (PIP)
(including list of
2.2 A procedure shall be in place to ensure correct part number and
applicable engineering
revision level as changes occur. This procedure shall also ensure
standards, software
affected documents (e.g. Control Plan, PFMEA, etc.) are updated and
level and hardware
applicable testing is performed for each change.
level) (MANDATORY
ENGLISH)
2.2.1 This procedure shall include communication and notification
Geometric
of changes throughout the Supply Chain. The Tier 1 Supplier is
Dimensioning &
responsible to ensure product shipped to Chrysler (or other
Tolerancing (GD&T)
designated manufacturing facility) is the latest revision level.
sheets (MANDATORY
ENGLISH)
2.2.2 This procedure shall include the receipt of an approved
Part number cross
Chrysler Change Notice. The Supplier shall not make any
reference sheet (if
changes without DOCUMENTED approval from the customer
applicable)
(i.e. voicemail, e-mail, etc. are UNACCEPTABLE).
Engineering Change
procedure
2.3 Where the product identity is not inherently obvious, the Supplier
Document Control
shall employ an internal numbering system and provide a cross
procedure
reference which enables users to identify the Chrysler part number
and revision level which corresponds to the Suppliers numbering and
revision system.
2.4 The Supplier shall have a process which prevents uncontrolled or
out of date documents from existing on the manufacturing floor (e.g.
Document audit). Refer to ISO/TS-16949, cl. 4.2.3.
Engineering Standards Identified
2.5 A process shall be in place to obtain revisions to all Chrysler,
governmental, Safety <S>, and other product related standards and
specifications. Chrysler standards are available to Suppliers via
Engineering Standards Supplier Distribution (ESSD)
https://essd.extra.chrysler.com/ESSD/Login.jsp.
2.5.1 This process shall address notification to applicable
departments of standard changes as they occur. This process shall
also include the frequency and responsibility for reviewing the
standards (not to exceed two working weeks; reference ISO/TS16949, cl. 4.2.3.1 Engineering Specifications).
2.6 The PSO Team shall verify that the CATIA Comment page or Part
Information Page (PIP) lists all applicable standards, including, but not
limited to, those shown on the source package and signed DVP&R (see
3.2 through 3.4).
2.6.1 Chrysler approval for deviations from required standards
shall be documented on the CATIA Comment page/PIP and
DVP&R.
15
ELEMENT 2 - PART NUMBER, DESCRIPTION AND CHANGE LEVEL, CONT.

2.6.2 The PSO Team shall verify that the CATIA Comment
page/PIP lists all sub-components of the end-item assembly. This
listing shall include the Chrysler part number (if applicable),
Supplier part number, quantity, and revision level.
2.6.3 The PSO Team shall verify that all dimensional requirements
are defined on the GD&T sheets and attached to the design model.
The Supplier shall consistently apply a mutually agreed upon (with
the Chrysler SQE and Product Engineer) datum scheme
throughout the part development process.
16
ELEMENT 3 - DESIGN FMEA

3.1 Design FMEAs (DFMEAs) shall be created using the latest AIAG
and Chrysler guidelines. If AIAG and Chrysler guidelines conflict,
Chrysler guidelines take precedence. See the AIAG Failure Mode
Effects Analysis (FMEA) manual and Appendix B of this manual.
Documentation
DFMEA (MANDATORY
ENGLISH)
Best Practice
procedure
3.2 The Supplier shall have an internal best practice procedure used
in the development of DFMEAs. It shall include documentation and
data which explains how the DFMEA severity, occurrence, and
detection numbers were developed.
3.2.1 This procedure shall be reviewed periodically for effectiveness
and include lessons learned with inputs from past issues (e.g.
eCIMS, NCT, warranty, CSA, yard holds, etc.).
3.2.2 The procedure shall include a process for continuous
evaluation and improvement of failure modes listed in the DFMEA.
This process shall have a method to determine which failure modes
are the highest risk, and address those first.
3.3 Error proofing and controls shall be identified in the DFMEA.
3.4 The DFMEA shall be a living document traceable to all design
changes. It shall contain all special characteristics (see Element 12).
3.5 A DFMEA shall be completed for each unique Supplier-designed
product. The Chrysler Product Engineer shall have lead responsibility
for reviewing and ensuring that the DFMEA is acceptable. The
Supplier shall have lead responsibility for ensuring that the DFMEA
meets all requirements. All DFMEA activities shall be completed on or
before required quality gate timing.
3.6 The DFMEA shall include all sub-components of the end-item
assembly.
3.7 The Supplier shall ensure all failures observed during Engineering
Development (ED) and Design Verification (DV) testing are captured
within the DFMEA.
3.8 The Supplier shall ensure the occurrence and detection ability of
failures observed during DV testing correlate with the occurrence and
detection values documented on the DFMEA.
3.9 Buzz-Squeak-Rattle (BSR) and Noise-Vibration-Harshness (NVH)
issues shall be addressed, as applicable.
NOTE: Special attention (as defined by Chrysler Engineering) should
be given to failure modes with:
A Severity 8, regardless of Occurrence or Detection values.
A Severity 5 and Occurrence 4, regardless of Detection (this
equates to high customer dissatisfaction).
A Detection of 10.
17
ELEMENT 4 - TEST SAMPLE SIZES AND FREQUENCIES

Documentation
4.1 Products covered under a Performance Standards (PF) that specify
Chrysler Engineering
test sample sizes, test frequencies, and acceptance criteria shall have
signed DVP&R
testing requirements included in a Design Verification Plan and Report
(MANDATORY
(DVP&R) and a Test to Failure verification plan, if applicable.
ENGLISH)
Reference the Chrysler Product Assurance Testing manual.
Applicable Engineering
Standards
4.2 Design Verification (DV) and Production Validation (PV) test plans
(MANDATORY
shall be signed by the Chrysler Product Engineer prior to testing.
ENGLISH)
Chrysler Engineering
4.2.1 PV Testing shall be preceded by successful DV Testing,
signed DV and PV test
unless waived in writing by the Chrysler Engineer.
plans (MANDATORY
ENGLISH)
4.3 Completed DV and PV test results shall be accepted and signed by
Annual Validation
the Chrysler Product Engineer.
procedure
4.4 All functional requirements shall be defined in the DVP&R and
verified against applicable Performance Standards for accuracy.
4.4.1 Deviations from the Performance Standards shall be
documented on the CATIA Comment page/PIP and DVP&R (e.g.
changes to test sample sizes, test waivers, etc.). See 2.6.1.
4.4.2 Continuous Conformance testing shall be documented on
the DVP&R when applicable.
4.4.3 A "circle grid analysis", or other formability analysis, is
necessary for PSO approval on stamped components if required by
the Chrysler SQE and/or Engineer.
4.4.4 Chrysler internal stamped components shall meet the
requirements in MQAS 90-6710 Dimensional Buy-Off Procedure
for Upgrading Stamped Parts During Die/Tool Development.
4.5 All testing failures shall be documented on the DVP&R and
addressed with a Chrysler 8-Step Corrective Action plan (available on
the Forever Requirements webpage through COVISINT and internally
through the electronic Book of Knowledge).
4.6 Annual validation testing shall be completed each year as specified
in the Chrysler Product Assurance Testing manual and applicable
Performance Standards, unless waived in writing by the Chrysler
Product Engineer and SQE. Reference ISO/TS-16949, cl. 7.5.2.
NOTE: A written waiver is required for each year that annual
validation will not be performed.
4.6.1 The Supplier shall have a procedure to ensure on-time
Annual Validation and prevent scheduling conflicts and
fixture/testing shortages in the event of multiple Annual
Validations.
18
ELEMENT 5 - PROCESS FMEA

5.1 Process FMEAs (PFMEAs) shall be created using the latest AIAG
and Chrysler guidelines. If AIAG and Chrysler guidelines conflict,
Chrysler guidelines take precedence. See the AIAG Failure Mode
Effects Analysis (FMEA) manual and Appendix B of this manual.
Documentation
PFMEA (MANDATORY
ENGLISH)
Best Practice
procedure
5.2 The Supplier shall have an internal best practice procedure used
in the development of PFMEAs. It shall include documentation and
data which explains how the PFMEA severity, occurrence, and
detection numbers were developed.
5.2.1 This procedure shall be reviewed periodically for effectiveness
and include lessons learned with inputs from past issues (e.g.
eCIMS, NCT, warranty, CSA, yard holds, etc.).
5.2.2 The procedure shall include a process for continuous
evaluation and improvement of failure modes listed in the PFMEA.
This process shall have a method to determine which failure modes
are the highest risk, and address those first.
5.3 Error/mistake proofing and controls shall be identified in the
PFMEA.
5.4 The PFMEA shall be a living document, reviewed and updated for
all process and/or product changes, as necessary. It shall contain all
special characteristics (see Element 12).
5.5 The Chrysler SQE shall have lead responsibility for reviewing and
ensuring that the PFMEA is acceptable. The Supplier shall have lead
responsibility for ensuring that the PFMEA meets all requirements. All
PFMEA activities shall be completed on or before required quality gate
timing.
5.6 The PFMEA shall reflect the entire manufacturing process.
5.7 The Supplier shall ensure that all failure modes observed during
pre-production runs are captured on the PFMEA.
5.7.1 The Supplier shall ensure the rate of occurrence and ability
to detect failures observed during pre-production runs correlate
with occurrence and detection values documented on the FMEA.
5.8 BSR and NVH issues shall be addressed, as applicable.
NOTE: Special attention should be given to failure modes with:
A Severity 8, regardless of Occurrence or Detection values.
A Severity 5 and Occurrence 4, regardless of Detection (this
equates to high customer dissatisfaction).
A Detection of 10.
19
ELEMENT 6 - PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN

Documentation
6.1 The process flow diagram shall represent the entire manufacturing
Process Flow Diagram
process from receiving through shipping operations, including main(or equivalent)
line assembly processes and off-line supply processes.
(MANDATORY
ENGLISH)
6.1.1 The process flow diagram shall include the processing
Manufacturing Floor
sequence, method, and equipment used at each station (including
Plan
inspection and repair/rework stations).
Work Station Layout
6.1.2 Stations which measure special characteristics and/or
contribute to significant nonconformances shall be identified.
6.2 The manufacturing floor plan shall document the layout of the
facility and the station-by-station flow of the manufacturing process.
6.2.1 The manufacturing floor plan shall highlight all production
equipment used.
6.2.2 The manufacturing floor plan shall show Work in Process
(WIP), raw material, and scrap/non-conforming material storage
locations.
6.2.3 The work station layout shall identify all work stations used
in the process.
6.3 The flow diagram, manufacturing floor plan, and/or work station
layout shall include each unique machine number.
layout shall include the number of operators (including float
operators) required per station (including repair/rework stations). The
PSO team shall verify the number of operators during the PDR.
layout shall identify bottleneck operations or stations.
6.6 All production equipment appearing on the manufacturing floor
plan, flow diagram, and work station layout shall be verified by the
PSO team during the PSO On-Site Visit.
20
ELEMENT 7 - CONTROL PLAN & PROCESS MONITORING

Documentation
7.1 The Control Plan shall describe each step of the manufacturing
Control Plan
process including, but not limited to: receiving, material handling and
(MANDATORY
storage, in-process operations, testing, inspections, rework/repair,
ENGLISH)
shipping, temporary or interim operations (e.g. back-up operations),
1st piece approval
and continuous conformance. Refer to the AIAG Advanced Product
procedure & records
Quality Planning (APQP) and Control Plan manual.
Control Charts
Process Performance/
7.1.1 Measurement and inspection frequencies detailed in the
Capability results
Control Plan, including all inspections for appearance
Log Sheets
requirements, shall be verified by the PSO Team during the PDR.
Defect Tracking Sheets
Craftsmanship Quality
7.1.2 Repair/rework stations shall have controls equal to or
Initiative procedure (if
exceeding those of the primary production line.
applicable)
Appearance Manual (if
7.1.3 The Control Plan shall include verification of Mistake
applicable)
Proofing (e.g. number of pieces, frequency, etc.).
7.1.4 The Supplier shall have a process which links their FMEAs
to the Control Plan. This process shall ensure that controls,
lessons learned, etc. detailed in the FMEAs are carried forward into
the Control Plan.
7.1.5 Controls implemented on similar products due to nonconformances (e.g., e-CIMS, warranty, NCTs, yard holds) shall be
included in the Control Plan. See 1.3 and 1.3.1.
7.1.6 All product and process control parameters and tolerances
shall be documented in the Control Plan.
7.1.7 All special characteristics identified in the GD&T
documentation and DVP&R which describe material, process,
performance, reliability, quality, and/or design requirements
identified in the PFMEA shall be included in the Control Plan.
7.1.8 Sample sizes shall be based on industry-standard statistical
sampling plan tables or shall use Statistical Process Control (SPC).
Process Monitoring
7.2 The Supplier is responsible for maintaining manufacturing
process performance/capability and shall have a procedure requiring
documented corrective actions for all out-of-control measurements.
Reaction plans shall include containment of suspected nonconforming
product and 100% inspection (approved by the PSO Team).
7.2.1 The Supplier shall maintain a minimum CP and CPK of 1.33
for on-going process capability. See 20.2.
7.3 The Supplier shall have a documented First Piece Approval
procedure which verifies proper set-up at each station and that parts
made meet applicable specifications.
21
ELEMENT 7 - CONTROL PLAN & PROCESS MONITORING, CONT.

7.3.1 The procedure shall require First Piece Approval at the
beginning of each shift or production run and after any changes
are made to the production process (e.g. tooling modifications,
process adjustments, etc.).
7.3.2 The process shall include the retention of the first piece until
the end of the shift or production run, identification of the first
piece sample(s), and analysis of special characteristics.
7.3.3 The process shall include verification of the last piece
produced at the end of the shift or production run against the
approved First Piece sample.
7.3.4 Documented evidence of First Piece Approval process
execution shall be maintained. The Supplier shall record the part
number, manufacturing date, and any additional information as
required by the PSO Team.
7.4 All inspection stations shall have a method of defect tracking (e.g.
tally sheets, scrap sheets, etc.).
7.5 Visual displays of process performance (e.g. FTC, scrap, rework)
and total production maintenance (e.g. downtime) shall be present and
up-to-date on the manufacturing floor.
7.5.1 Targets shall be identified for each metric with documented
plans for achieving those targets. Progress toward achieving targets
shall be documented and tracked.
7.6 Where SPC methods are used, the Supplier is required to maintain
a history of component production sequence, production line,
production tool, and characteristics values. See the Chrysler
Customer-Specific Requirements for ISO/TS-16949, cl. 4.1.1.
7.7 Suppliers shall have a Craftsmanship Quality Initiative Procedure
for all components with appearance requirements. This procedure
shall include team members, regular scheduled Craftsmanship
reviews and audits, an issue resolution tracking matrix, creation and
approval of Boundary Samples, and the retention of an Appearance
Manual for each part. See 10.4-10.4.4 for Boundary Sample
requirements.
7.7.1 Suppliers shall have an Appearance Manual for all
components with appearance requirements. This manual shall
include appropriate documentation (sign-off sheet, table of
contents, revision history, general appearance characteristics
acceptance specification), studio quality photos of product shown
in appropriate views, studio quality photos for any deviation from
design intent, and Craftsmanship worksheets (e.g., photos of
conditions, containment and permanent correction actions, along
with supporting documentation).
22
ELEMENT 8 - INCOMING & OUTGOING MATERIAL CERTIFICATION PLAN

Documentation
Incoming Material Certification Plan
Incoming Material
8.1 The Incoming Material Certification Plan shall include procedures
Certification plan
used to certify incoming material prior to releasing into production.
Sampling plans
Receiving Reports
8.2 The plan shall derive inspection frequency on component and subInspection/test reports
tier history.
Copies of sub-tier
Supplier Certificates of
8.2.1 The plan shall include an escalation process which
Analysis for each
increases the inspection frequency when a defect is found.
specific subcomponent
8.2.2 When the plan includes dock to stock (i.e. parts
Copies of sub-tier
shipped directly from the receiving area without inspection) the
Supplier PSWs (Part
process shall require at least three previous, consecutive, defectSubmission Warrant)
free shipments without subsequent nonconformances.
Copies of sub-tier
Supplier ISO-9001
8.3 The plan shall include incoming acceptance sampling plans, for
certifications
both attribute and variable data. Two or more of the methods
Outgoing Material
described in cl. 7.4.3.1 of ISO/TS-16949 shall be used; otherwise, the
Certification Plan
minimum requirements found in the Lot Acceptance Sampling Table
Audit Work
(Appendix B) apply. Inspection frequencies and sampling plans shall
Instructions
be documented in the Control Plan. Lot size shall not exceed one shift
Shipping reports
or one production run, whichever is smaller.
Audit Records
IMDS process
NOTE: The requirements in the Lot Acceptance Sampling Table are
only for attribute sampling. SPC is superior and if used, the sampling
quantities in the Lot Acceptance Sampling Table need not be followed.
8.3.1 The incoming acceptance sampling plan frequencies shall be
based upon the assigned risk level of the purchased material or
component (see 1.2.2).
8.4 The plan shall identify all processes performed by sub-tier
Suppliers (e.g. plating, heat-treating, etc.) and include records of
inspection/test results that relate to the appropriate lot code.
8.5 The incoming lot acceptance date (or date the lot was inspected)
shall include the year, month, day and numeric sequence.
8.6 Sub-components or production materials used in the end-item
assembly shall have full PPAP (or equivalent). The PSW for each subcomponent shall be easily accessible.
8.6.1 Incoming materials or components shall meet all Chrysler
appearance requirements of the final assembly, if applicable.
8.7 Certificates of Analysis shall comply with all standards/
specifications identified on the CATIA Comment page or PIP.
8.8 The Supplier shall have copies of their sub-tier Suppliers ISO9001 certification on file.
23
ELEMENT 8 - INCOMING & OUTGOING MATERIAL CERTIFICATION PLAN, CONT.

Outgoing Material Certification Plan
8.9 The Outgoing Material Certification Plan shall include procedures
to qualify product prior to shipment to the customer.
8.10 The plan shall include outgoing acceptance sampling plans for
both attribute and variable data. Inspection frequencies and sampling
plans shall be documented in the Control Plan and consider the
severity, occurrence, and detection values of a potential defect (per the
PFMEA).
8.11 The outgoing lot acceptance date (or date the lot was inspected)
shall be identified by the year, month, day, and production sequence.
8.12 Certificates of Analysis, if required by Chrysler for the finished
product, shall comply with all standards/specifications identified on
the CATIA comments page or PIP.
8.13 Shipping, Audit, and Containment Records shall be documented
and maintained.
8.14 The Supplier shall have a process for Material/Substance
Composition reporting via the International Materials Data System
(IMDS). IMDS is available at http://www.mdsystem.com/index.jsp.
8.14.1 Components shipped to Chrysler (or Chrysler-designated)
facilities shall have an IMDS number listed on the PSW.
24
ELEMENT 9 - PARTS HANDLING PLAN

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

part of the Packaging Instructions and/or Preventive Maintenance.
See Elements 10 and 19.
9.3 A method shall exist to clearly identify and differentiate rework/
repair, scrap, WIP bins, etc.
NOTE: Chrysler does not procure returnable containers for Suppliers
WIP (Work in Process) or for sub-tier Suppliers. Containers for WIP are
the responsibility of the Supplier and/or sub-tier Supplier. Use of
Chrysler containers for this purpose is unacceptable and considered
misappropriation of Chrysler corporate assets. Z and/or A PSO
approval cannot be given until appropriate corrective actions are
implemented.
9.4 The plan shall include the procedures for in-process raw material
re-stock (e.g. Kan-Ban) and inventory control (e.g. FIFO).
9.4.1 Material storage locations shall be clearly identified.
9.4.2 When FIFO is used as a method of inventory control, the
Supplier shall have an effective method of ensuring FIFO stock
rotation throughout the manufacturing facility.
9.5 The plan shall have a procedure by which material is tracked and
moved from one process to another (e.g. travelers, routing cards, etc.).
9.5.1 Information shall include lot number, date, number of pieces
entering/exiting the operation, number of pieces reworked/
repaired, number of pieces scrapped, operation number and shift.
9.6 All parts shall have lot control and traceability through all stages
of production (including all sub-tier Suppliers and shipping, if
applicable), and be documented and verified (cl. 7.5.3 & 7.5.3.1 of
ISO/TS-16949). Lot size shall not exceed one shift or one production
run, whichever is smaller.
9.6.1 Sorted, reworked or repaired material shall be traceable back
to the sort, rework or repair process.
9.6.2 Part traceability shall be independent of inventory control
processes (i.e., shall not be FIFO-dependent).
25
ELEMENT 9 - PARTS HANDLING PLAN, CONT.

9.7 The plan shall include containment of nonconforming material and
use of the Chrysler Supplier Notification of Potential Nonconformance
process. See the Forever Requirements website available through
COVISINT.
9.7.1 The plan shall include handling and identification of nonconforming product, from receiving of returned material from the
customer to final disposition.
9.7.2 The plan shall include the maximum amount of time allowed
for disposition of quarantined product. Reviews of quarantined
product shall occur daily, at a minimum.
9.7.3 The plan shall include proper coordination with Chrysler
regarding purging suspect material, part and container
identification for replacement material, and logistics and
scheduling of replacement material.
9.7.4 The Supplier shall have a locked and/or controlled area for
holding nonconforming, quarantined, or non-production product
(e.g. engineering samples). Product in the holding area shall be
clearly identified with part number, number of pieces, date
quarantined, reason for quarantine, and expected disposition date.
Electro-Static Discharge (ESD) Requirements
9.8 Manufacturing facilities handling components that must be
protected from ESD shall have the following:
ESD mats and/or floors
Heel and/or wrist straps (ESD certified shoes are acceptable)
ESD testers for operators to verify heel and wrist straps, and/or
shoe effectiveness. All ESD testers shall have up-to-date operator
instructions and be included in the calibration procedures and
schedule, as well as in the Preventive Maintenance plan
Clearly-identified ESD containers (e.g. bags, totes, etc.) for
transporting ESD-sensitive product
ESD workbenches that are grounded with plugs for wrist straps,
if applicable
ESD gloves and/or finger cots for handling of PCB's (e.g. rejects)
9.8.1 All ESD operators shall be properly trained and identified
(e.g. badges, buttons, etc.).
9.8.2 Work instructions for ESD testers shall require ESD testing
of all personnel before they enter the ESD production location.
9.8.3 The Supplier shall have an ESD certification schedule which
mandates recertification of all ESD equipment, tools, testers,
containers, and personnel on an annual basis (minimum). Records
of the certification and the recorded measurements shall be kept.
9.8.4 The ESD manufacturing process shall be included in the
Suppliers Layered Process Audit (LPA) plan.
26
ELEMENT 10 - OPERATING INSTRUCTIONS

10.1 All instructions, including but not limited to: operator, set-up,
changeover, First Piece Approval, Mistake proofing, rework/repair,
gage operation, inspection, and packaging, shall be approved and
signed by the appropriate Supplier departments (e.g. Quality,
Engineering, Manufacturing, etc.). They shall be dated and traceable
to the level of parts being produced, and shall include sample sizes
and frequencies.
10.1.1 Special characteristics shall be identified in Operating and
any other appropriate instructions.
10.1.2 All instructions shall enable any adequately trained person
to perform the described operation.
10.2 The Supplier shall have a process for training and qualifying key
personnel prior to performing production operations (e.g. classes,
mentorship, temporary supervision, etc.). Key personnel training
records shall be documented and maintained.
Documentation
Operator instructions
Set-up instructions
Changeover
instructions
First Piece Approval
instructions
Mistake proofing
instructions
Rework/repair
procedures and
instructions
Gage operation
instructions
Inspection instructions
Key Personnel training
& qualification process
Boundary Sample
verification procedure
10.2.1 A list of training requirements for each unique workstation

shall be maintained.
10.2.2 Visual inspection stations shall have methods established
to verify the operators ability to identify defects (e.g. periodic
testing, recertification, etc.).
10.2.3 Operations requiring special certification (e.g. rework/
repair, gauging), and operators certified to perform them, shall be
identified.
10.2.4 All key personnel needed to ensure that the Suppliers
process(es) can meet the required volume at launch shall be hired
and fully trained, and a plan shall be in place to support full
production volume.
10.3 All instructions, control charts, defect tracking sheets, log
sheets, and reaction plans shall be located adjacent to the process,
visible to the operator and legible (reference ISO/TS-16949, cl.
7.5.1.2). Visual management techniques (e.g. displays, pictures,
diagrams, etc.) shall be used whenever possible.
10.4 Process Boundary Samples used for pilot production shall be
reviewed and approved by the Chrysler PSO Team. Boundary Samples
for the start of regular production shall be obtained during the PDR
and reviewed and approved by the Chrysler PSO Team.
10.4.1 The Supplier shall have a procedure which periodically
(every 3 months, at a minimum) verifies the condition of designated
Boundary Samples to ensure they are still acceptable.
NOTE: The Boundary Sample verification procedure may be
included in the Suppliers Preventive Maintenance Plan, if desired.
See Element 19.
27
ELEMENT 10 - OPERATING INSTRUCTIONS, CONT.

10.4.2 The Supplier must attach a Boundary Sample tag to each
Boundary Sample with the following information: part name, part
number, date that the Boundary Sample is valid until, description
of the Boundary Samples purpose, and appropriate Supplier
management signature (and Chrysler signature, if required).
10.4.3 The Supplier shall maintain Boundary Samples in a secure
place. Three (or more) sets of Boundary Samples shall be provided
to Chrysler, if required.
10.4.4 Boundary samples used to determine acceptance criteria
for design characteristics (regardless of process capability) shall be
approved by the Chrysler Engineer.
10.5 The Supplier shall have a process to ensure workstation
organization and cleanliness (e.g. 5-S) which is implemented daily (at
a minimum). Evidence of completion shall be maintained.
10.5.1 Necessary items on or near workstations (e.g. tools, subcomponent stock) shall be stored in designated areas. Small tools
or similar items should be secured to the workstation.
10.5.2 During the PSO On-site Visit, the PSO Team shall verify
that work areas are free of trash and unnecessary items and all
other items are in their designated areas (except when in use).
Rework and Repair Instructions and Procedures
10.6 The Chrysler PSO team shall approve all permanent rework and
repair operations, procedures, and work instructions.
10.6.1 All reworked or repaired products shall be clearly and
uniquely identified. See 9.6.1.
10.6.2 The rework/repair procedure and instructions shall state
that when a sub-component is replaced which has Safety <S>
characteristics, the lot from which the replacement sub-component
came shall be identified and it shall be linked with the final
assembly on which it was used.
10.6.3 The rework/repair procedure and instructions shall state
that when a sub-component is removed from an assembly which
has been returned from a Chrysler facility and re-used in another
assembly, the lot code of all sub-components with Safety <S>
characteristics shall be identified and traceable to the new
assembly in which the component was used.
10.6.4 The rework/repair procedure and instructions shall require
traceability in the event that any part returned from a Chrysler
assembly plant is to be re-sent without rework or repair performed
(e.g. parts sorted as good from a returned, quarantined lot).
28
ELEMENT 10 - OPERATING INSTRUCTIONS, CONT.

10.6.5 The Supplier shall have a procedure describing how
temporary rework/repair operations are created and controlled.
This procedure shall include:
Identification of all personnel responsible for creating
temporary rework operations, instructions, and controls.
Notification and approval from Chrysler through the
Forever Requirements prior to initiating temporary rework
(and issuance of an IAA or CN, if necessary).
Requirements that rework/repair parts go through controls
(including Error and Mistake proofing) equivalent or
superior to the primary production line (see 13.4).
29
ELEMENT 11 - TOOLING, EQUIPMENT, AND GAGES IDENTIFIED

Documentation
11.1 The Supplier shall establish a tooling list which includes all
Tooling list
production and interim tooling, fixtures, gages, and equipment used in
Supplier Tool Record
the production process.
(STR)
11.1.1 The list shall indicate ownership (e.g. Supplier owned,
Chrysler owned, other OEM, etc.) for each item listed.
11.2 All Chrysler owned tooling, fixtures, and gages shall be clearly
and permanently marked with the same tool number as identified on
the Supplier Tool Record (STR) and the Tool Purchase Order, and be
identified Property of Chrysler. The method used to mark the tools
shall be non-degradable and fireproof (paint, ink, paper tags, etc. are
unacceptable methods of marking). All tooling, equipment, gages and
fixtures shall possess unique identification numbers. See ISO/TS16949 cl. 7.5.4 and the Chrysler Purchase Order. The STR can be
obtained through the Supplier Quality Portal (under the Summaries
header and Part Summary sub-header).
11.2.1 Chrysler-owned gages shall be manufactured and approved
per the Chrysler gage standards on the Advance Manufacturing
Engineering (AME) website http://ame.ctc.chrysler.com/gages.
11.2.2 The PSO Team shall verify the STR against the Suppliers
production process during the PSO On-Site Visit. If tooling, gages,
and/or fixtures reside at a sub-tier Supplier, the sub-tier location
shall be indicated on the STR.
11.2.3 Chrysler-owned tooling shall only be used for the
production of Chrysler product(s).
11.3 All tooling, fixtures, equipment, and gages used in the
production process (e.g., from the laboratory, production, tool room,
maintenance, quality, etc.) shall be identified in the Suppliers
maintenance, storage, and calibration procedures.
30
ELEMENT 12 - SPECIAL CHARACTERISTICS IDENTIFIED

12.1 The Supplier shall develop a list of special characteristics using
Chrysler input and their own knowledge of the product. Special
characteristics are product characteristics or manufacturing process
parameters which affect safety, fit, function, performance, compliance
with regulations, or subsequent processing of product. They include
all governmental, Key (diamond) <D>, and Shield (safety <S> and
emissions <E>) characteristics. Torque requirements and
characteristics identified as SPC points on the design model shall also
be considered special characteristics. Other characteristics deemed
critical to the process or component may also be designated as special
characteristics by the Supplier and/or PSO Team. See the AIAG
Production Part Approval Process manual and the Chrysler CustomerSpecific Requirements for ISO/TS-16949.
AND FPSC
Documentation
List of special
characteristics
Prototype build part
layouts
FPSC Plan & Results
(MANDATORY
ENGLISH DOC)
Master Tracking List (if
applicable)
12.1.1 Special characteristics shall be noted on applicable quality

documents (e.g. Control Plan, DFMEA, PFMEA, DVP&R, set-up and
operator instruction sheets, etc.).
12.1.2 The Supplier shall have documented definitions of internal
special characteristics and the requirements for their selection,
control, and monitoring.
12.2 All special characteristics shall be included in the Measurement
System Report and the Initial Process Study. See 15.4 and 20.1.2.
Safety Characteristics
12.3 A process shall be established and maintained to track Safety
(<S>) related activities including a listing of all Safety (<S>)
characteristics (also referred to as a Master Tracking List). This list
shall provide overall Safety related coordination and assist in
developing primary and secondary measurements. Engineering
Standards shall be shown or referenced on affected procedures and
work instructions for processing and verification during production.
12.3.1 The Supplier shall use SPC on all Safety (<S>)
characteristics that shall be made available to Chrysler
representatives upon request. See PF-SAFETY for additional
requirements and information regarding Safety (<S>)
characteristics.
NOTE: For special characteristics not identified as Safety (<S>)
characteristics or SPC points on the design model, SPC is not
required unless specified by the PSO team.
12.3.1.1 Each Safety (<S>) designation shall have both a
(100%) primary measurement process and a secondary QC
Audit measurement process designed to maintain lot control.
12.3.1.1.1 The primary measurement shall be performed by
production operators or skilled trades / Manufacturing
Engineering (ME) personnel for robotics, equipment, dies,
fixtures, tools, gages, etc. as determined locally.
31
ELEMENT 12 - SPECIAL CHARACTERISTICS IDENTIFIED AND FPSC, CONT.

12.3.1.1.2 The secondary measurements (QC Audit) shall
have Quality Auditors performing visual and/or physical
checks at specific sample sizes and frequencies and
recording results on statistical charts.
12.3.1.1.3 The acceptable checking method, sample size
and sample frequency for establishing lot control within the
Suppliers facility shall be determined by the Suppliers
Control Plan and/or as directed by the Chrysler PSO Team.
12.3.2 A process shall be in place and maintained which tracks
any nonconformances related to Safety (<S>) characteristics,
including proper corrective action notification, verification of
implementation, and carrying forward lessons learned.
12.3.2.1 Detection of any nonconformance during sample
verifications shall result in the immediate quarantine of all
product, with disposition determined by the PSO Team.
12.3.3 Regular process audits on Safety (<S>) characteristics shall
be performed as a part of the overall control plan OR as specified
by the Chrysler PSO Team. In addition, Chrysler may perform
audits and/or elect to have a third party audit completed.
12.4 FPSC shall be performed on all new or modified components,
including those undergoing a Forever Requirements (FR) change,
regardless of risk level. It shall include parts from all production lines
and tool cavities. FPSC begins at Gate C S1 Start for new parts, or at
the first production shipment for modified parts and FR changes.
12.4.1 The duration of FPSC shall be determined by the AQP
Team. It shall be for a minimum of the first 2000 inspected, defectfree parts shipped to each Chrysler or Chrysler-designated facility,
or for a time period that lasts until V1 + 90 days.
NOTE: Modified components, components undergoing a Forever
Requirements change, and Low risk programs all default to a
duration of 2000 inspected, defect-free parts, unless otherwise
required by the Chrysler AQP and/or PSO Team.
12.4.2 The Supplier shall provide the FPSC plan and results from
previous shipments for PSO team review at the Pre-PSO meeting.
Corrective actions for non-conformances found during FPSC shall
be approved by the Chrysler AQP and/or PSO Team and
implemented before the PSO On-site Visit occurs.
12.4.3 If a defect is found during FPSC, the entire quantity or
duration shall be repeated (i.e., 2000 additional pieces or duration
extended, as appropriate).
12.4.4 FPSC-designated areas or stations shall have work and/or
inspection instructions, visual displays, and be included in the
Suppliers LPA process, as appropriate.
32
ELEMENT 13 - ERROR AND MISTAKE PROOFING

Documentation
13.1 The Supplier shall have an Error and Mistake Proofing Plan
Error and Mistake
which describes the development, implementation, use, and
Proofing Plan
maintenance of error and mistake proofing within the organization.
Mistake Proofing
Contingency Plan
NOTE: Error proofing eliminates, by design, the possibility of
producing a specific defect. Mistake proofing identifies errors in
production and prevents them from becoming non-conformances.
13.1.1 The plan shall include the creation of Verification Samples
for checking mistake proofing. These shall include all failure modes
identified in the FMEAs.
13.1.2 Verification Samples shall be tested on the production line
to ensure mistake proofing is operational. Frequency of verification
shall take into account start of shift, production changeover, major
disruptions, tooling maintenance, etc. Verification shall occur
once per shift or per production changeover (whichever is more
frequent) at a minimum. It shall also occur following any
unplanned disruption or down time. See 14.4.2 and the Chrysler
Customer-Specific Requirements for ISO/TS-16949 cl. 4.2.9.1.
13.1.3 Verification Samples shall be clearly marked, labeled, and
controlled to prevent mixing with production materials. They shall
be stored separate from WIP or finished product in a clearly
marked container or designated area.
13.1.4 Error and mistake proofing software shall be tested for all
known failures and bypass scenarios.
13.2 Line or station lock out shall be implemented at all process steps
to prevent failed operations from proceeding to a subsequent station
or into finished product. Audible and visual indicators shall notify of
the failed operation. Corrective actions shall be implemented prior to
restarting the line or station.
13.2.1 The Supplier shall have a contingency plan in the event the
production mistake proofing is not operable. A visual and/or
audible alert shall signify the mistake proofing is inoperable. The
plan shall include notification of the Chrysler SQE via the Forever
Requirements.
13.3 All failure modes identified in the FMEAs with a severity of 8 or
higher shall have error proofing, if possible. Those failure modes that
cannot have error proofing in place shall have mistake proofing.
13.4 Error and/or mistake proofing shall be used on all special
characteristics.
13.5 All reworked or repaired product shall pass through error and
mistake proofing equal or superior to the primary production line.
13.6 Error and mistake proofing verification shall be included in the
Preventive Maintenance Plan.
33
ELEMENT 13 - ERROR AND MISTAKE PROOFING, CONT.

13.7 Sequential sensing shall be used when the process includes
physically independent cells making up one process flow.
13.8 Stations used as final verification (e.g. end-of-line (EOL) tester,
vision station, etc.) shall leave unique identification proving that the
part has successfully passed through the entire process. Error and/or
mistake proofing shall ensure that parts cannot skip this operation.
13.8.1 Mistake proofing shall verify that the end-item assembly is
correct and complete.
NOTE: Verifying that the component is in the machine prior to
assembly, and then assuming it is on the finished product after the
machine cycle is not acceptable.
13.9 All functions, efforts and travel shall be exercised and measured
to their full extent 100% on line.
13.10 All sub-components shall have 100% verification of proper part
selection through error and/or mistake proofing.
13.11 All cylinders applying components or performing staking shall
be verified for full stroke.
13.12 Manufacturing processes (e.g. Injection Molding, Welding, Heat
staking, etc.) shall have controllers (e.g. RJG, MACO etc.) with closed
loop feedback systems maintaining established process limits.
13.13 All critical lubrication, adhesive points, liquids and gases shall
be automated and have error and mistake proofing for proper flow,
amount, and location.
13.13.1 Leak testing for liquids and gas shall be automated
and measured 100% on line.
13.14 Assembly machines that accommodate right and left parts in
the same process shall have error and/or mistake proofing to ensure
proper assembly and packing.
NOTE: The PSO Team may require separate paths for right- and lefthanded parts, if necessary.
13.15 The Supplier shall have error and/or mistake proofing to
prevent loose foreign objects in assembly.
Requirements for Electrical Components
13.16 Electrical connections shall have a positive detent that can be
identified through audio, tactile or visual feedback.
13.17 Electrical components and connections shall have continuity
and functional check with automated line stop/lockout if continuity is
not achieved.
34
ELEMENT 13 - ERROR AND MISTAKE PROOFING, CONT.

13.18 Terminal contact for in-process manufacturing (harness
assembly, engine testing, device testing, etc.) shall meet the following:
Pogo pins shall not violate the contact area of the terminal(s)
being tested
Pogo pins shall be maintained and inspected regularly
The test fixture shall align the connector to the test fixture prior
to engagement of the pogo pins
When pogo pin access is not provided and spring member
contact is the only option, the probe used to contact the terminal
spring member shall be smaller in thickness than the minimum
blade thickness (including tolerances) of the terminal being
tested. If round pin terminals are being tested, the male pin
probe shall be smaller than the minimum diameter (including
tolerances) of the pin.
The depth of insertion of the probe shall be the minimum
necessary for electrical contact testing.
Requirements for Modules/Sequenced Part Delivery (SPD)
13.19 Barcodes and/or pick lights with break beams (or equivalent)
shall be used to ensure correct part selection and assembly per the
broadcast.
13.20 Vision systems and/or color sensing shall ensure correct
components and color match (where applicable).
13.21 Push-click-pull methods shall be used for electrical and other
applicable connections.
13.22 SPD part sequence shall be maintained throughout the entire
process, including rework and repair.
13.23 The Supplier shall have backup systems to ensure
uninterrupted receipt of broadcast.
13.24 Components with Safety <S> characteristics shall be traceable
to the VIN sequence.
13.25 Rebroadcasts due to non-repairable conditions shall have
additional tracking to maintain sequence and timely delivery.
35
ELEMENT 14 - LAYERED PROCESS AUDIT

14.1 Layered Process Audit (LPA) is a system of audits performed by
multiple levels of the Suppliers management. Special characteristics
(and other characteristics designated by the Supplier and/or PSO
Team) and error/mistake-proofing are audited for process
conformance. Reference the Chrysler Customer-Specific Requirements
for ISO/TS-16949 cl. 4.2.9.1 and the LPA Fundamentals course
(available through TEDS) for additional LPA requirements.
14.2 The LPA plan shall have procedures and work instructions for
each level of management detailing roles and responsibilities. The plan
shall include handling of nonconformances discovered during the
audit as well as a schedule frequency and structure chart.
14.3 The LPA plan shall require top management reviews of LPA
results. It shall state the frequency of management reviews and
require documented meeting minutes and/or open issues.
Documentation
LPA procedures
LPA work instructions
LPA Structure and
Frequency Chart
LPA Process Control
Audit Checklist
LPA Error Proofing
Verification Audit
Checklist
List of individuals
responsible for
updating LPA
LPA Implementation
Plan (for new
Suppliers)
14.4 The Supplier shall complete a Process Control Audit Checklist

and an Error and Mistake Proofing Verification Audit Checklist.
Examples of each can be found in the LPA course training manual.
14.4.1 The Process Control Audit shall be done once per shift (or
as agreed to by the PSO Team) by a group leader or supervisor.
Management audits shall be done weekly. Manufacturing areas
shall be divided and auditors rotated so that all areas are included.
14.4.2 The Error and Mistake Proofing Verification Audit shall be
completed once per shift or product change-over (whichever comes
first) and whenever an unscheduled disruption occurs in the
production line. The audit shall be performed by qualified, trained
personnel only. See 13.1.3.
14.4.3 After PSO approval, no item shall be removed from the LPA
checklists without the Chrysler SQEs approval regardless of risk.
14.4.4 All nonconformances discovered at Chrysler manufacturing
facilities (at any program stage) shall be included in the LPA.
14.5 The Supplier shall demonstrate at least one level of an LPA
during the PSO On-Site Visit. The LPA shall be on all processes
undergoing PSO (not necessarily every part).
14.6 The Supplier shall maintain a list of trained individuals who are
responsible for developing, implementing, and updating the LPA plan.
14.7 Suppliers without an existing LPA process (e.g., new Suppliers to
Chrysler) shall have an LPA Implementation Plan which includes an
action plan and timing for incorporating LPA across their facility.
Processes of highest risk shall be the first to implement LPA.
NOTE: The Supplier should consider customer quality issues, process
capability, FTC, items identified as high risk on the PFMEA, operatordependant operations, and amount of available error/mistake-proofing
when determining which processes are the highest risks.
36
ELEMENT 15 - SUPPLIER READINESS EVALUATION & MEASUREMENT SYSTEM REPORT

Documentation
Supplier Readiness Evaluation (SRE)
Supplier Readiness
15.1 Prior to the Pre-PSO Meeting, the Supplier, with concurrence
Evaluation (SRE) Run
from the Chrysler PSO team, shall determine part quantity for the SRE
results
run. The PSO team shall determine (and agree upon) the required
Measurement System
Line Speed (see 16.1.1), as well as the number of components and
Report
characteristics to be inspected. SRE results shall be recorded on the
Supplier Readiness Evaluation/Trial Run Results form and reviewed
by the Chrysler PSO Team before or during the Pre-PSO Meeting. The
Chrysler PSO Team shall determine SRE results to be acceptable
before scheduling the PSO On-Site Visit.
15.1.1 The Supplier shall present SRE results for each production line
and/or tool used in the process.
15.2 The Supplier shall conduct the SRE on the latest released
Production Part Number(s) with an approved Purchase Order (P.O.).
The stated part number shall have a corresponding Production Tool
P.O., with related tooling capable of meeting the required capacity and
line speed(s).
15.2.1 All tooling and equipment shall be at production level,
unless otherwise approved in writing by the Chrysler PSO team
and Chrysler SQE Manager before the SRE is run.
15.3 During the SRE run, the Supplier shall measure and document all
characteristics on all parts per the Control Plan, regardless of stated
Control Plan frequency.
15.3.1 Process performance calculations (PP and PPK) are required
for all special characteristics.
15.3.2 In the case of multiple production lines and tools, process
performance calculations are required for each line and/or tool.
15.4 Prior to Gate C S1 Start, actual station cycle times and FTC
shall be determined and recorded on the Supplier Readiness
Evaluation form. The PSO Team shall review the data during the PrePSO meeting.
15.4.1 The AQP and/or PSO Team shall meet prior to Gate C - S1
Start and determine requirements for station cycle time, based on
the overall line speed requirement.
15.5 The Supplier shall demonstrate a First Time Capability (FTC) of
90% or greater prior to Gate C S1 Start. Deviation from this
requirement shall have signed approval from the Chrysler PSO Team
and the SQE Manager.
NOTE: The FTC requirement applies only to the primary production
line. Secondary, off-line, and/or support processes do not require
90% FTC, unless specified by the PSO Team.
37
ELEMENT 15 - SUPPLIER READINESS EVAL. & MEASUREMENT SYSTEM REPORT, CONT.

15.5.1 For multiple production lines, tools, and/or cavities, FTC
shall each be calculated separately.
NOTE 1: FTC is equal to the number of acceptable parts produced
divided by the total number of parts run. See Appendix C FTC
Calculations.
NOTE 2: Rework and repair are NOT counted in the number of
acceptable parts, nor are parts initially rejected by the process but
found to be acceptable after re-testing.
15.6 PV test parts shall be selected from a trial run/SRE that meets
the requirements listed in 21.1.
Measurement System Report
15.7 During the PSO On-Site Visit, PSO Team members are required
to randomly select and witness the measurement of product and/or
process characteristics (including sub-component characteristics).
Results shall be documented on the Measurement System Report
form. This audit is typically completed before or during the PDR.
Examples:
Stock thickness for a stamped part
Moisture content, mold pressure or temperature for a
molded part
Solder-ability, dimensional checks or reflow oven profile
for an electronic printed circuit board assembly
15.7.1 The PSO team shall decide the characteristics and quantity
of parts to be witnessed for measurement verification prior to the
PSO On-Site. All special characteristics shall be included (see
12.2).
15.7.2 A minimum of 3 characteristics on 30 parts shall be
measured.
15.7.3 The PSO team shall determine the acceptability of the
measuring process for each characteristic identified on the report.
15.7.4. Process and/or component nonconformances found while
performing the measurement verification shall have root cause
analyses performed, and corrective actions approved by the PSO
Team and implemented by the Supplier, before PSO approval can
be given.
38
ELEMENT 16 - PRODUCTION DEMONSTRATION RUN

Documentation
16.1 During the Pre-PSO Meeting, the PSO Team (including the
Production
Supplier) shall review and determine the required production line
Demonstration Run
speed, Daily Tooling Capacity, and Net Operating Time for Chrysler
(PDR) form (with line
Parts. These items shall be verified with the Chrysler Buyer.
speed calculation)
Process constraints
16.1.1 The PSO team shall ensure the Supplier meets the P.O.
and contingency plans
Daily Tooling Capacity and operating pattern.
NOTE: In situations where multiple Purchase Orders (P.O.s) exist
for the same part (e.g., for some high volume parts or parts
supplied to both US and Mexican Chrysler assembly plants), the
Daily Tooling Capacities from both P.O.s are added together before
determining the required production line speed.
16.2 The Production Demonstration Run (PDR) shall be conducted on
all production lines of record, using production tools, production
processes, and fully trained operators.
16.2.1 The PDR consists of 300 pieces (i.e., end-item assemblies)
or two hours of production, whichever is more stringent. These
requirements apply equally to multiple production lines and/or
multiple sets of tools.
NOTE: Rework, repair, and scrap are not included in the PDR line
speed calculation. The line speed calculation only includes
completed, successfully produced assemblies. If the line is empty
at the start of the PDR, line fill time is not included. Count
completed units only, starting with the first completed assembly off
the production line.
16.3 The PSO Team shall witness and monitor the production line
speed during the PDR and record the data on the Production
Demonstration Run form. For multiple production lines and/or tools,
the line speed for each line and tool shall be recorded.
16.4 Process constraints (bottlenecks), which may impact quality
or production schedules shall be documented on the Comments
Sheet, and contingency plans shall be documented and submitted to
the PSO team for approval.
16.4.1 When process constraints are attributed to high scrap,
rework and/or repair (i.e. FTC < 90%), the issue shall be
documented on the Comments Sheet and the Supplier shall
identify root cause, implement permanent corrective actions and
verify corrective action with a new PSO On-Site Visit prior to
receiving A or Z approval.
16.5 Parts made during the PDR may be used for PPAP if and only if
all PPAP requirements, including statistical requirements, have been
successfully completed.
39
ELEMENT 16 - PRODUCTION DEMONSTRATION RUN, CONT.

16.6 The Supplier shall demonstrate a First Time Capability (FTC) of
90% or greater. Deviation from this requirement shall have signed
approval from the Chrysler PSO Team and the SQE Manager.
NOTE: The FTC requirement applies only to the primary production
line. Secondary, off-line, and/or support processes do not require
90% FTC, unless specified by the PSO Team.
16.7.1 For multiple production lines, tools, and/or cavities, FTC
shall each be calculated separately.
NOTE 1: FTC is equal to the number of acceptable parts produced
divided by the total number of parts run. See Appendix C FTC
Calculations.
NOTE 2: Rework and repair are NOT counted in the number of
acceptable parts, nor are parts initially rejected by the process but
found to be acceptable after re-testing.
NOTE 3: FTC is required for both Gate C S1 Start and the PDR.
40
ELEMENT 17 - PARTS PACKAGING AND SHIPPING SPECIFICATIONS

Documentation
17.1 The Parts Packaging and Shipping Plan shall specify the
Parts Packaging and
containers (expendable or returnable) used to ship product to Chrysler
Shipping Plan
or Chrysler-designated facilities.
Packaging and
Shipping Procedures
17.1.1 Specific information shall include but is not limited to
Packaging, shipping
returnable and/or back-up expendable: container dimensions,
and labeling
container material, pieces per container, weight of full and empty
instructions
container, number of containers per pallet, etc.
Returnable Container
Management Plan
17.1.2 Shipping and labeling instructions shall conform to the
Bar coded labeling
Chrysler Packaging and Shipping Instructions manual. This can
procedure
be obtained through COVISINT or eCopier (84-263-8537).
Shipping label
example
17.1.3 The Supplier shall be responsible for designing,
Shipping Test Results
manufacturing, testing, and documenting expendable packaging
test data (simulated or actual).
17.1.4 Testing (e.g. shaker table, rail or over the road etc.) shall
be performed based upon the mode of transit.
17.2 When returnable containers are used, a Returnable Container
Management Plan shall be developed which includes:
Training and access to the Chrysler Container Management
System (CMS).
A procedure for mandatory data entry.
Inventory control to track containers on hand and in transit.
Procedures for mandatory transmittal of container and/or part
number information during ASN submissions from the
Suppliers facility.
Identification and disposition of contaminated or damaged
containers.
17.3 The expendable backup plan shall cover a shortage of returnable
containers and ensure on-time shipment. Backup expendable
packaging shall maintain the same dimensions as the returnable
container and hold the same number of pieces.
17.3.1 Both expendable and returnable packaging shall be sized
not to exceed the Chrysler assembly plant requirement of twohours-of-plant-production per container. Deviation requires
approval from Chrysler Material Handling Engineering (MHE).
17.4 Simulation tests and/or shipping tests shall be conducted prior
to S1Start and be documented.
17.5 When Chrysler designed packaging is used (i.e. containers,
racks, etc.), the Supplier is not responsible for packaging approval(s).
17.6 PSO approval shall not be delayed due to a lack of
approval(s) for Chrysler provided and/or designed packaging.
Any questions concerning approval of Chrysler-designed packaging
should be referred to Chrysler MHE.
41
ELEMENT 17 - PARTS PACKAGING AND SHIPPING SPECIFICATIONS, CONT.

Bar Code Labeling
17.7 When bar code labeling is done as the final operation of the
assembly process (i.e. at end-of-line), labels shall be generated one at
a time and only following successful completion of the previous
operation (e.g. after passing an end-of-line tester, after correct
scanning of the correct material, etc.).
17.8 The Supplier shall have logic in place to prevent printing of
duplicate bar code labels.
17.9 The Supplier shall ensure (through logic or error and/or mistake
proofing) that part bar code labels match the part for scanning
purposes.
42
ELEMENT 18 - GAGE AND TEST EQUIPMENT EVALUATION

Documentation
18.1 Gages used in the process shall be included in the Control Plan.
Gage R&R results
Gage layout results
18.2 The Supplier shall refer to the Design and/or Process FMEA to
Gage and test
determine the appropriate gage to be used (attribute or variable).
equipment validation
procedure
18.3 The Supplier shall have a procedure to validate gages and test
Gage and test
equipment (and results) prior to release onto the manufacturing floor.
equipment calibration
Reference the AIAG Measurement System Analysis manual.
records
Calibration schedule
18.4 All gages and testing equipment shall have acceptable R&R
studies performed prior to the Pre-PSO Meeting. Variable data gage
R&R studies are preferred for all types of gages and fixtures.
18.4.1 Total R&R as a percent of part tolerance shall be used for
new processes. Total R&R as a percent of process variation shall
be used for process improvement.
18.4.2 Acceptable gage R&R as a percentage of tolerance shall be
less than 10%. The gage R&R as a percent of study variation shall
also be less than 10%. A gage R&R between 10% and 30% shall
require approval from the Chrysler PSO team (greater than 30% is
unacceptable).
18.4.3 For attribute gages the Supplier shall complete a study per
the AIAG Measurement System Analysis manual or shall use a
minimum of 50 samples, three operators, and three sets of
measurements from each operator. The samples shall include parts
that are representative of each side of the specification(s). All
measurements taken on parts that are out of specification shall
indicate that the parts are to be rejected.
NOTE: Attribute gauging is unacceptable on special characteristics
unless approved by the Chrysler PSO Team.
18.5 For variable gages, tolerances used for 100% verification shall be
reduced by the extent of gage R&R.
18.6 All gages and test equipment shall be calibrated and reflect the
last calibration and expiration dates. Calibrations shall be traceable to
a known source and/or standard.
18.7 A calibration schedule shall be established for all gages and test
equipment. There shall be detailed procedures for calibration of any
equipment done internally (i.e. at the Supplier).
18.7.1 The Supplier shall have a system to ensure calibration of
equipment is done per schedule. A reaction plan shall be
established for containment of equipment that is out of calibration.
18.7.2 3rd party sources used for gage and test equipment
calibration shall be evaluated by the Supplier and be certified to
ISO/IEC 17025. See ISO/TS-16949 cl. 7.6.3.2.
43
ELEMENT 19 - PREVENTIVE MAINTENANCE PLANS

Documentation
19.1 A Preventive Maintenance (PM) plan shall exist for all equipment
PM Plan (includes
and tooling. The PM plan shall:
schedules, frequencies,
instructions, etc.)
Identify key process equipment and provide resources for
machine/equipment maintenance
Identify planned maintenance activities
Detail storage/preservation of equipment, tooling and gauging
Detail availability of replacement parts for key equipment
Include reporting and progress towards maintenance goals
The plan is a living document which shall be reviewed and updated on
a regular basis or as circumstances require. Reference ISO/TS16949:2002 cl. 7.5.1.4.
19.1.1 The Supplier shall utilize predictive maintenance methods
to continually improve its preventive maintenance system.
19.1.2 The Supplier shall have backups/replacements available
for parts with long-lead replacement times.
19.2 The PM plan shall include schedules, responsibilities, and
instructions for maintaining each item of equipment. The plan shall
outline how all frequencies were established for each piece of tooling
and/or equipment (e.g. quantitative historical data of frequencies,
material specifications, etc. and their collective impact on equipment).
19.3 PM schedule conformity, machine performance issues, and PM
related quality issues shall be reviewed for process optimization. The
PM plan is a living document and shall include lessons learned from
similar tooling and/or equipment.
19.4 The Suppliers PM process shall ensure preventive maintenance
is performed per the established schedule.
19.5 New tooling and/or equipment shall be added to the PM schedule
prior to production release.
19.6 The PM plan shall address storage of tooling and equipment
when not in use. This plan shall provide guidelines to ensure all
tooling and equipment is clean, well protected from damage and
environmental stresses, properly maintained, and easy to locate.
19.7 The Supplier shall ensure that, as tooling and/or equipment
approaches the predetermined end of life cycle, appropriate actions
are taken. These actions shall ensure conformity to Chrysler
production, assembly, and quality requirements (e.g. increased
inspections, enhanced detection measures or methodologies).
19.8 The PM plan shall address 3rd party and/or outsourced PM
activities when applicable.
Tooling and/or equipment with 3rd Party outsourced PM
activities shall be uniquely identified on the schedule.
The 3rd Party sources shall have a PM process equal to or
better than that of the Supplier.
44
ELEMENT 20 - INITIAL PROCESS STUDY

20.1 The Initial Process Study part quantity shall be determined by
the PSO Team during the Pre-PSO Meeting and documented on the
Initial Process Study form. All parts used in the Initial Process Study
shall come from the PDR.
Documentation
Initial Process Study
Results
20.1.1 The Performance Matrix (see Appendix B) shall be used to

determine the PP and PPK requirements for the Initial Process
Study. For attribute characteristics, the PP and PPK requirements
do not apply; however 100% of the parts shall be acceptable.
20.1.2 All identified special characteristics shall be included in the
Initial Process Study, as well as any other characteristics required
by the PSO Team. Any characteristic or measurement taken
automatically by the process (e.g. end of line tester checks,
continuity checks, etc.) shall also be included in the study.
20.1.3 If the process performance is less than the established
requirement, then 100% verification of shipped parts is acceptable
as an interim corrective action only with Chrysler PSO Team
approval. However, the Initial Process Study shall be marked
Reject on the PSO SUMMARY form. Permanent corrective actions
must be approved by the Chrysler PSO Team, implemented by the
Supplier, and another On-Site Visit performed (and approved) prior
to Z or A approval being granted.
20.1.3.1 Characteristics which do not meet process
performance or capability requirements shall have a corrective
action plan approved by the Chrysler PSO Team and fully
implemented (and meet or exceed those requirements) before
PSO approval can occur.
NOTE: 100% mechanical verification (i.e. mistake proofing) may be
accepted as permanent corrective action at the discretion of the
Chrysler SQE.
20.1.4 PP and PPK shall be calculated individually for each line,
tool, and/or cavity.
20.2 For on-going production after PPAP submission, the Supplier
shall maintain process capability with a minimum CP and CPK of 1.33.
45
ELEMENT 21 - PRODUCTION VALIDATION TESTING COMPLETE

Documentation
21.1 Test samples used in Production Validation (PV) testing shall
Component level PV
come from the SRE or equivalent trial run and meet the following:
test results (DVP&R)
All process performance (PP and PPK) requirements are met, or
PV Test procedures
100% dimensionally inspected.
Training/certification
The SRE/trial run met the required station cycle time and FTC.
records for BSR
All sub-components and materials used in the run had an
operators
approved PPAP (or equivalent).
Appearance Approval
Report (AAR) (if
Production processes and tooling were used.
applicable)
All gages and testing equipment have acceptable R&R results.
21.1.1 When a single production line and/or tool will be qualified,
or multiple lines and/or tools qualified on separate tests, the PV
test components shall be selected randomly from each line or tool.
21.1.2 When multiple production lines and/or tools will be
qualified in a single PV test, a portion of the PV test components
shall be randomly selected from each production line and/or tool
in proportion to that lines contribution.
NOTE: Random selection of parts ensures that the full range of
process variation will be accounted for during PV testing.
21.1.3 Test samples used for PV testing shall meet the production
design release model.
21.1.4 When rework or repair processes are agreed upon by the
Chrysler PSO team, parts from those processes shall be included in
PV testing.
21.2 PV test results shall be reviewed by the PSO Team and accepted
and signed by the Chrysler Product Engineer (see 3.2 and 3.3).
21.3 The DVP&R shall be updated with PV testing results.
21.4 Component level PV testing shall be successfully completed on all
test samples by Gate C S1 Start. If one (or more) test samples fail, it
is unacceptable to replace only the failed samples. The PV test plan
shall be repeated on new samples after corrective actions are
implemented.
NOTE: Additional PV testing, such as System-level (including
Powertrain systems) and Vehicle-level, may still be required before all
PV testing is considered accepted and completed. All levels of PV
testing are required to be accepted and completed before PSO A
Approval can be given.
BSR/NVH
21.5 BSR/NVH testing results shall be included in the DVP&R,
reviewed by the PSO Team, and accepted and signed by the Chrysler
Product Engineer (see 21.2).
46
ELEMENT 21 - PRODUCTION VALIDATION TESTING COMPLETE, CONT.

Documentation
21.5.1 Analyses shall include evaluations of interactions with
mating parts to reduce, eliminate, and/or monitor objectionable
BSR or NVH characteristics. Potential causes shall be addressed in
the FMEAs, DVP&R, and the Control Plan. It is the Suppliers
responsibility to ensure their parts do not exhibit any BSR/NVH
conditions within their environments.
21.5.2 The Supplier shall employ detailed procedures and/or test
methods to properly detect BSR and NVH without subjectivity.
The procedures are to recreate BSR and NVH, as found through
Chrysler testing and/or defined boundary samples (e.g. sound
chamber, shaker and actuation tests).
21.5.3 The Supplier shall have training and/or certification for
employees conducting BSR/NVH operations (e.g. hearing tests).
Appearance Approval Report (AAR)
21.6 Parts or components with appearance requirements shall have
an approved AAR from the Chrysler Design Office before PSO A
approval is given.
NOTE 1: Interim appearance approval is insufficient for PSO A
approval. Parts shipped to Chrysler (or Chrysler-designated) facilities
with interim appearance approval require an IAA.
NOTE 2: For Asian programs and Suppliers, the Chrysler Design
Engineer may be responsible for signing the AAR, rather than the
Design Office.
47
48
APPENDIX A
FORMS & INSTRUCTIONS
49
50
List suggested launch deviation if risk

cannot be mitigated (if applicable)
Long Term Fix - Production

Permanent Corrective Action Plan
Containment Activities / Actions

Required to Protect Launch

Issue (Include CN number and Build
Phase):


Phase):


Phase):


Phase):
Applicable Risk Driver(s) (Insert X

in box for risk, R for remove, A for
add - first time only)
Risk Drivers / Concerns
Applicable Risk Driver(s) (Insert X

in box for risk, R for remove, A for
add - first time only)
Risk Drivers / Concerns
CNs (CNs required to be

implemented into tooling for
next/current build phase):
IAA Status (IAA # / Status for
next/current build phase):
Error / Mistake
Proofing
Implemented
(S2)
Key Milestones/Events
IRE Risk (High/Medium/Low):

Issue
Daily Tool Cap /

Operating Pattern
Process
Capability (S1)
Other - Please Specify
Appearance Approval
Report Accepted (S2)
Comments
Date
Description
MRD
Completion Date
(P / A):
Completion Date
(P / A):
Completion Date
(P / A):
Completion Date
(P / A):
Supplier Management /
Financial Stability /
Historic Performance
Design /
Change
Activity
Greenfield
Location
Assigned To (Name):
Assigned To (Name):
Assigned To (Name):
Assigned To (Name):
Other - Please Specify
Mix / Volume
Changes /
Releases
Causal Factors
Lead Program - AQP specific dates

Projected Start Projected Completion Date
Date
Late Sourcing /
Resourcing
Pre-PSO Mtg
PSO Visit/PDR
PV Testing
PPAP Dim/Lab
Gate A - V1
Date
Lead Program - CDS Gate Dates
Key Component?:
Next AQP Mtg Date:
Revision date:
Gate D1 - S0 Start
Gate C - S1 Start
S2 Start
Mitigation Plan for current build phase (S1, S2, V1). List issues in order of most significant (highest risk). Include Actual Verse Target information
Component PV Testing
Complete (S1)
Equipment, Fixtures, Facilities,

and Gages Complete (S1)
Y/N
Outbound
Personnel Hiring /
Shipping Racks / Training Complete
Dunnage (S1)
(S2)
Executive review date / Mgt. level (High Risk only)
Primary Production Tools Complete?

Equipment, Facilities, & Fixtures Complete?
Cycle Time & FTC Complete?
Production Demonstration Run Complete?
Description
Parent Company:
Supplier Name:
Supplier Code(s)/Mfg. Location:
Ship to Location
(Chrysler plant/module supplier):
Highlight significant risk to launch risk drivers/concerns in red.
Line Speed
Required
Sub-Supplier(s)
Primary Production
Station Cycle Time /
Readiness (S2) Tooling Complete (S1)
FTC (S1)
Risk Drivers -
Design Records
CPV concur with P.O.? (Procurement responsibility)
Supplier actual daily tool capacity and actual work pattern concur with P.O.?
Production Demonstration Run Requirements

P.O. Work
Purchase Order Created?
P.O. / CPG Daily Tool
Pattern (Yes / No)
Capacity
SH /HR /DAYS
M.Y./Vehicle Line:
Part Name:
Part Number(s):
Chrysler AQP Executive Summary
51
Status
eCIMS Tracking
Name
Supplier Name
Key or High Risk Sub - Suppliers (Tooling & equipment and/or components)
Description (Tooling/Equipment
Supplier Location
Managing Group (AH,
description or component part name)
NEA, Mexico, EU, Tier
1, Tier 2, etc.)
Week 2
Week 3
Days w/o Nonconformance:

Week 4
Week 5
Implementation Date
Email
Approved / InProcess
V1
S2
S1
Target Date /
Actual Date
Process
Documentation
21 elements for North America, 18

for Asia
PSO Summary
Elements Complete
Status of parts - Prototype parts, prototype process, home line, fully debugged, less PDR, etc.
Week 1
Permanent Fix
Supplier Core Team Members

Position
Phone Number
Account Manager
Quality Manager
Program Manager
Plant Manager
First Production Shipment Certification - FPSC

Quantity (Number of Pieces):
Assembly Potential Customer Potential
FTC or Pp / Ppk
Failure Mode
Failure Mode
Email
Burst Builds (BB) /Trial Runs (TR) - Burst Build is any run at rate based on P.O. Daily Tool Capacity and Work Pattern using production parts. Trial runs are
all other builds.
Date
P/A
Quantity
BB/TR
Duration
Parts / Hour
Effect of Potential Failure Mode
FPSC Finish Date:
Issue Description
Chrysler Core Team Members

Position
Phone Number
Supplier Quality Engineer (SQE)
SQE Manager
Buyer
Release Engineer
Top Product Specs (Customer Impact)
FPSC Start Date:
Supply / Capacity Issues
eCIMS Number
Name
52
Name
Responsible Team Member
Chrysler Core Team Members

Position
Phone Number
Supplier Quality Engineer (SQE)
SQE Manager
Buyer
Release Engineer
Issue / Description
M.Y./Vehicle Line:
Part Name:
Part Number(s):
Email
Open Date
Name
Target Closed Date
Parent Company:
Supplier Name:
Supplier Code(s)/Mfg. Location:
Ship to Location
(Chrysler plant/module supplier):
AQP Open Issues
Supplier Core Team Members

Position
Phone Number
Account Manager
Quality Manager
Program Manager
Plant Manager
Actual Closed Date
Email
Comments / Resolution
Key Component?:
Next AQP Mtg Date:
Revision date:
53
1.2
1.3
2.5
7.2
8.1
8.9
9.8
10
10.6
11
12
12.3
12.4
13
SQE
SQE
ENG
ENG
ENG
ENG
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
14
15
15.1
15.6
16
17
17.7
18
19
20
21
21.5
21.6
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
SQE
ENG
ENG
DO
SQE
Component-level
S-1
EF
Start
S2
S-2
Month-Date
Month-Date
V1
Month-Date
STATUS
REQUIRED
Indicates Quality Gates Review
All
Y,
Y,
Y,
Y,
G,
G,
G,
G,
Safety Characteristics
Error and Mistake Proofing
Y,
G,
Special Characteristics Identified and FPSC
Y,
Y,
Y,
Y,
Y,
Y,
Y,
Y,
Y,
Y,
G,
G,
G,
G,
G,
G,
G,
G,
G,
G,
Supplier Readiness Evaluation
Production Demonstration Run
Parts Packaging and Shipment Specifications
Gage and Test Equipment Evaluation
Preventive Maintenance Plans
Y,
Y,
Y,
G,
G,
G,
BSR/NVH
Appearance Approval Report (AAR)
DO: Design Office
ENG: Release Engineer
CURRENT DAY
ACTUAL
Y,
Production Validation Testing Complete
G,
Bar Code Labeling
Layered Process Audit

Supplier Readiness Evaluation and
Y,
G,
Requirements for Modules/Sequenced Part Delivery

(SPD)
Y,
Y,
G,
G,
Y,
Y,
G,
G,
Y,
G,
Tooling, Equipment, and Gages Identified
Rework & Repair Instructions and Procedures
Operating Instructions
Electro-Static Discharge (ESD) Guidelines
Parts Handling Plan
Y,
G,
Outgoing Material Certification Plan
Y,
G,
Y,
Y,
G,
G,
Y,
G,
Incoming Material Certification Plan
All
Y,
Y,
Key
G,
Y,
G,
Incoming and Outgoing Material Certification

Plan
Process Monitoring
Process Flow Diagram and Manufacturing Floor

Plan
Control Plan and Process Monitoring
Process FMEA
G,
Test Sample Sizes and Frequencies
Y,
Y,
G,
G,
Y,
G,
Y,
Circle one only "G" "Y"

or "R"
Design FMEA
Engineering Standards Identified
Part Number, Description, and Change Level
ACTION PLAN
If "Y" or "R", you must

provide an Action
If "Y" or "R", you must provide
Plan.
an Action Plan.
Y,
YEAR
Month-Date
Month-Date
G,
G2
Month-Date
D2
Month-Date
Problem Solving
S-0
Month-Date
All
D1
Month-Date
Y,
Month-Date
G,
Key
EF
YEAR
Month-Date
Supply Base Management
ACT
G2
EF
Month-Date
Y,
PLAN
END
# of Days Month-Date
G,
ACT
# of
Veh
G,
PLAN
BEGIN
MRD
REVISION DATE:
REVISION:
Quality Planning
SQE: Supplier Quality Engineer
13.19
SQE
Build Date
SUPPLIER RESPONSIBLE
PERSON
Build
Name
S0
S1
S2
V1
TIMING CHART
ADVANCE QUALITY PLANNING (AQP)
ITEM / ACTIVITIES
13.16 Requirements for Electrical Components
SQE
PSO
Element
Number
KEY MATERIAL/BUILD DATES
PART NAME(S):
PART NUMBER(S):
SQE
SUPPLIER:
SUPPLIER CODE:
SQE
CUSTOMER
LEAD
PSO Document Checklist Work Instructions
Header:
Enter Part Name, Number, Change Level, Program, Supplier,

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

(Green/Approved, Yellow/Corrections, Red/Missing,
Black/Not Applicable)
NOTE 1: Corresponding box on Checklist will fill in.

NOTE 2: This form is optional. It is intended as an aid in conducting the
Pre-PSO Documentation Review meeting only.
54
PART NAME(S)
SUPPLIER
MFG. LOCATION
PART NUMBER(S)
SUPPLIER CODE
PRE-PSO MEETING DATE
CHANGE LEVEL(S)
PSO ON-SITE VISIT DATE
PROGRAM
PSO ON-SITE VISIT NUMBER
PSO DOCUMENT CHECKLIST
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Not Applicable
Missing/Reject
Documentation / Task
Corrections
Sec.
Enter an "X" in the

appropriate box
Approved
All Documents
Approved?
1st Review Date:

2nd Review Date:
Required Action
1. Advance Qualiity Planning

1.1 AQP Process Schedule
1.1 AQP Timing Chart
1.1 AQP Gate Requirements and Tasks
1.1 AQP Open Issues
1.1 Execuive Summary
1.2 Supply Chain diagram
1.2 Risk of all sub-components and sub-tier processes
1.2 PSO/PPAP documentation for M/H risk sub-components
1.2 Sub-Tier Supplier quality performance
1.2 Sub-Tier Supplier "Forever" Requirements verification
1.3 Corrective action procedure
1.3 Procedure to convey Lessons Learned
Copies of eCIMS or 8-Step Corrective Actions for issues encountered
1.4
in previous pilot builds.
1.5 eCIMS/8-step corrective actions for previous issues
1.6 DOE
0
2. Part Number, Description & Change Level

2 GD&T sheets or Design drawings
2.2 Engineering Change procedure including CN tracking
2.3 Part number Cross reference
2.4 Document Control procedure
2.6 Catia files,drawing Comment Page/PIP
3. Design FMEA
3 DFMEA (Engineering responsible)
3.2 Best Practice Procedure
4. Test Sample Sizes and Frequencies
4 List of applicable engineering standards
Chrysler Engineering signed DV/PV test plans with Continuous
4.2
Conformance & Test to Failure plans.
4.4 Chrysler Engineering signed DVP&R
4.6 Annual Validation Procedure
5. Process FMEA
5 PFMEA
5.2 Best Practice Procedure
6. Process Flow Diagram & Manufacturing Floor Plan
6.1 Process Flow diagram
6.2 Mfg. Floor Plan
6.2 Workstation Layout
7. Control Plan and Process Monitoring
7.1 Control Plan
7.3 1st piece approval procedure & records
7.4 Defect Tracking sheets
7.5 Control charts
7.5 Process Performance charts
7.5 Log Sheets
7.7 Craftsmanship Quality Initiative procedure (if applicable)
7.7 Appearance Manual (if applicable)
8. Incoming and Outgoing Material Qualification Plan
8.1 Incoming Material Certification Plan
8.3 Sampling Plans
8.4 Receiving Reports
8.4 Inspection/test reports
8.6 Copies of sub-tier and supplier PSW's
Copies of sub-tier Certificate of Analysis for each specific sub8.7
component
8.8 Copies of sub-tier Supplier ISO9001 certifications
8.9 Outgoing Material Certification Plan
8.13 Audit Work Instructions
8.13 Shipping Reports
8.13 Audit Records
8.14 IMDS process
55
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
9. Parts Handling Plan - WIP

9.0 Parts Handling Plan
9.8 ESD procedures
0
11. Tooling, Equipment & Gages Identified

11.1 Tooling List (Including Capital Equipment)
STR List (printed from Chrysler system) Note: "Property of Chrysler"
11.2 and the STR number must be on all Chrysler owned tooling (fire-proof
and non-degradeable).
12. Special Product & Process Characteristics Identified
12.0 Special Characteristics List
12.0 Prototype build part layouts
12.4 Master Tracking list (if applicable)
12.5 FPSC Plan & Results
13. Error & Mistake Proofing
13.1 Error & Mistake Proofing Plan
13.2 Mistake Proofing Contingency Plan
14. Layered Process Audit Plan
14.2 LPA Procedures
14.2 LPA work instructions
14.3 LPA Structure and Frequency chart
14.4 LPA Process Control Audit checklist
14.4 LPA Error Proofing Verification Audit Checklist
14.6 List of individuals responsible for updating LPA
14.7 LPA Implementation Plan (if applicable)
15. SRE Results and Evidence of Product Specifications
15.1 Supplier Readiness Evaluation (SRE) Run results
15.4 Measurement System Report
16. Production Demonstration Run
16.1 Production Demonstration Run (PDR) form
16.4 Process Constraints & Contingency Plans
17. Parts Packing & Shipping Specifications
17.1 Parts packaging and shipping plan
17.1 Packaging and Shipping procedures
17.1 Packaging,shipping and labeling instructions
17.1 Shipping label example
17.2 Returnable Container management plan
17.4 Shipping test results
17.7 Barcoded Labeling Procedure
18. Gage & Test Equipment Evaluation
18.3 Gage layout results
18.3 Gage and test equipment validation procedure
18.4 Gage R&R (All measurement devices) results
18.6 Gage and test equipment calibration records
18.7 Calibration schedule
19. Preventative Maintenance Plans
19.0 PM Plan (Everything on Tooling list is in System)
20. Initial Process Study
20.0 Initial Process Study results
0
0
0
10. Operating Instructions
10.1 Operator Instructions
10.1 Set-up Sheets
10.1 Changeover instructions
10.1 1st Piece approval instructions
10.1 Mistake proofing instructions
10.1 Gage operation instructions
10.2 Key Personnel Training & Qualification process
10.3 Boundary sample verification procedure
10.4 Rework/repair instructions
21. Production Validation Testing Complete

21.0 Component level PV test results
21.0 PV test procedures including BSR & NVH
21.5 Training/certification for BSR operators
21.6 Appearance Approval Report (AAR) (if applicable)
56
CHRYSLER PROCESS SIGN-OFF CHECKLIST

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

DOCUMENTATION
1. ADVANCE QUALITY PLANNING

2. PART NUMBER, DESCRIPTION and CHANGE LEVEL
3. DESIGN FMEA
4. TEST SAMPLE SIZES and FREQUENCIES
5. PROCESS FMEA
6. PROCESS FLOW DIAGRAM and MFG FLOOR PLAN
7. CONTROL PLAN and PROCESS MONITORING
8. INCOMING and OUTGOING MATERIAL CERTIFICATION PLAN
9. PARTS HANDLING PLAN
10. OPERATING INSTRUCTIONS
11. TOOLING, EQUIPMENT and GAGES IDENTIFIED
12. SPECIAL CHAR IDENTIFIED & FPSC
13. ERROR and MISTAKE PROOFING
14. LAYERED PROCESS AUDIT
15. SUPPLIER READINESS EVAL & MEASUREMENT SYSTEM VERIF.
16. PRODUCTION DEMONSTRATION RUN
17. PARTS PACKAGING and SHIPPING SPECS
18. GAGE and TEST EQUIPMENT EVALUATION
19. PREVENTIVE MAINTENANCE PLANS
20. INITIAL PROCESS STUDY
PROCESS
Accept
Reject
N/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Accept
Reject
N/A
ADDITIONAL PSO PROCESS ELEMENTS REQUIRED FOR "A" APPROVAL

DOCUMENTATION
21. PRODUCTION VALIDATION TESTING COMPLETE
CORRECTIVE ACTION REQUIRED

ON-SITE REVISIT REQUIRED
Process Sign-Off Team
PROCESS
Accept
Reject
N/A
Accept
Yes
No
Date
Yes
No
Date
Reject
N/A
Manufacturing Facility
ENGINEERING
PRINT NAME, SIGN AND DATE
SUPPLIER QUALITY
57
PART NAME(S)
SUPPLIER
0
PART NUMBER(S)
0
0
CHANGE LEVEL(S)
PROGRAM
0
0
MFG. LOCATION
SUPPLIER CODE
1/0/1900
PSO COMMENTS SHEET

ITEM
ISSUE/ACTION
RESPONSIBILITY
TARGET
DATE
CLOSED
DATE
58
59
MFG. LOCATION
SUPPLIER CODE
SUPPLIER NAME
0
0
1/0/1900
Overall Process:
Station/Operation Description
Process /Part
USL
UCL
Part/Proc
Avg.
LCL
LSL
PERFORMANCE RESULTS
Pp
Quantity
Attempted
Quantity Accepted
Required Cycle Time
Ppk
Actual Cycle Time
STATION CYCLE TIME / FTC RESULTS
Meas.
Freq.
LINE RATE:
Quantity
Attempted
SHIFT:
Req. FTC
Quantity
Accepted
SUPPLIER READINESS EVALUATION / TRIAL RUN RESULTS
Process Feature /Part Characteristic
Station/ Operation
#
1
2
3
4
5
6
7
8
9
10
11
12
Item
#
QUANTITY RUN:
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
Actual FTC
% GR&R
ACC/ REJ
ACC/ REJ
Supplier Readiness Evaluation/Trial Run Results Instructions

Note: When requesting approval for multiple manufacturing lines, a SRE/Trial Run Results
form shall be completed for each manufacturing line requesting approval.
Quantity Run: Number of parts agreed by Chrysler and the Supplier prior to the run.
Line Rate: The calculated line rate for the Supplier Readiness Evaluation or trial run = Part Quantity Accepted
Duration of run.
Shift: The manufacturing shift the run was performed. Record shift # and hours. (e.g. 1st shift, 6am-3pm)
Process Feature/Part Characteristic: The process feature or part characteristic that is being measured.
Process/Part: Document if data is for a process measurement or a part measurement.
Meas. Freq.: Measurement Frequency. Record the number of part/process measurements taken per time interval.
USL: Upper Specification Limit. The upper limit of the part or process specification per the part drawing or process
standard.
UCL: Upper Control Limit: The upper limit established by the Supplier for process/part control. NOTE: This number
should be less than the USL.
Part/Proc. Avg.: Part/Process Average. The average of all measured process features/part characteristics.
LCL: Lower Control Limit. The lower limit established by the Supplier for process/part control. NOTE: This number
should be greater than the LSL.
LSL: Lower Specification Limit. The lower limit of the part or process specification per the part drawing or process
standard.
PP: The calculated PP for all measured process features/part characteristics.
PPK: The calculated PPK for all measured process features/part characteristics.
Quantity Attempted: The total number of part/process measurements taken.
Quantity Accepted: The total number of part/process measurements acceptable per the established controls (within the
LCL-UCL).
% GR&R: Calculated percentage of Gage R&R for gage used for part/process measurement.
Acc/Reject: Has the PSO team determined the suppliers data to be acceptable (acc) or unacceptable (Reject)? [i.e. LCL
<Proc Avg. < UCL; PP PPK matrix requirement (see Initial Process Study element); GR&R < 10% ; 10< GR&R < 30 PSO
team decision].
Station/Operation # and Description: Identification and short description of the operation.
Required Cycle Time: Cycle time calculated for that station based upon meeting overall required Line Speed.
Actual Cycle Time: Observed cycle time for that station.
Required FTC: First Time Capability required for that station (in order to meet overall FTC requirement of 90%).
Actual FTC: FTC observed for that station.
ACC/REJ: Do all stations meet or exceed their required cycle time (in order to meet the calculated Line Speed
Requirement)? Do all stations meet or improve upon their required FTC? (Overall FTC 90%?)
60
PRODUCTION DEMONSTRATION RUN

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

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

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

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

E) First time through fallout during the PDR
F) Length of PDR in hours
G) Acceptable parts witnessed at the PDR
Start:
hours/shift
Finish:
attempted parts
failed parts
hours
pieces
In process calculations:
H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)]
I) Available production hours/day [B1*H]
J) Chrysler required parts per hour at the PDR [A/I]
K) Witnessed parts per hour at the PDR [G/F]
hours/shift
hours/day
parts/hour
parts/hour
Requirements:
L) FTC calculation [((D-E)/D)*100]
M) Difference between witnessed parts/hour and required parts/hour [K-J]
%
pieces
0
61
Production Demonstration Run Calculation Work Instructions

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

C1) Lunches - The amount of time, in hours per shift, that the production process is not operating due to lunch.
C2) Breaks - The amount of time, in hours per shift, that the production process is not operating due to breaks.
C3) Changeover and/or set up - The amount of time,
in hours per shift, that the production process is not operating due
to changeover and/or set up activities. Only changeovers that were quoted to occur during the production operating
pattern should be considered for this calculation.
Changeovers or set up not conducted every shift should be calculated on a per shift basis (e.g. Changeover time per
week divided by the number of shifts per week = changeover time per shift).
NOTE: Please indicate when during the production process the changeovers will be implemented (if they are conducted
during the quoted operating pattern, or if they are to be conducted during "off shifts").
C4) Operating time dedicated to other customers - The amount of time,
in hours per shift, that the production process is
operating/manufacturing product for other customers.
Operating time dedicated to other customers calculated on a per shift basis (e.g. operating time per week divided by the
number of shifts per week = changeover time per shift).
C5) Scheduled/unscheduled downtime not considered - The amount of downtime,
in hours per shift , that was not
considered. This could be any downtime such as PM, changeover, etc. that was not included in the development of the
shift pattern/pieces per day quantity.
Scheduled/unscheduled downtime should be calculated on a per shift basis (e.g. operating time per week divided by
the number of shifts per week = changeover time per shift).
D) The parts attempted during the PDR are the total number of parts the supplier produced including rejects/scrap.
E) First time through fall out during the PDR is the number of parts that were rejected from the manufacturing process during
first evaluation. This is not the final number of unacceptable parts, but only those that failed
first time through the
process. (This number will be used in the FTC calculation.)
F) Length of PDR in hours is the measured time it took to conduct the production demonstration run. Please input start and
finish time in cells provided.
G) Acceptable parts witnessed at the PDR are the total number of parts, minus any rejects, which were demonstrated during
the production run. (May differ from first time through fallout.)
62
Production Demonstration Run Calculation Work Instructions, cont.

H) Available production hours/shift are the net hours per shift the supplier has available to build product not including any
scheduled downtime.
I)
Available production hours/day are the net hours per day the supplier has available to build product.
J) Chrysler required parts per hour at the PDR are the total number of acceptable parts the supplier must produce, in an hour's
time, necessary to satisfy Chrysler.
K) Witnessed parts per hour at the PDR are the number of acceptable parts witnessed by the PSO team, which the supplier
produced within an hour's time.
L) FTC (First Time Capability) is the percentage of acceptable parts witnessed at the production demonstration run out the
total number of parts attempted at the PDR.
If the Chrysler requirement of 90% or greater is met, the cell will turn green.
If the Chrysler requirement is not met (less than 90%), the cell will turn red.
NOTE: If the FTC is less than 90%, the PSO team shall take product and process technology, complexity, supplier
experience, and the effectiveness of defect containment actions into account when deciding whether the demonstrated lower
FTC values are acceptable with a documented deviation. A Chrysler Supplier Quality Manager's signed approval is required for
deviation from the PSO FTC requirement.
M) The difference between required parts/hour and witnessed parts/hour gives the total number of parts over or under the
Chrysler requirement.
If the part difference is greater than (the Chrysler required parts per hour + 10% ), the cell will turn green indicating the
line speed is acceptable. i.e. (J + 10%) M, then cell = green (requirements met).
If the part difference is between 0 and (the Chrysler required parts per hour + 10% ), the cell will turn yellow indicating the
line speed has met requirements, but the part difference is very close and may require additional attention.
i.e. 0 <= M < (J+10%) then cell = yellow.
If the part difference is less than 0 , the cell will turn red indicating the requirement is not met. i.e. M < 0 the cell = red.
NOTE: In the event (M) is yellow, it is strongly advised to conduct an Extended Run PSO to stress the supplier's
production line and increase confidence in the supplier's ability to meet Chrysler requirements. PSO Extended Run
options are explained in the PSO manual. Continuous improvement actions should also be developed for bottleneck
operations or other operations which showed poor performance during the PSO run.
63
64
P025 Gap - Machine 66
P025 Gap - Machine 67
Process Feature / Part

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

Characteristic
Item
#
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
Process /Part
Meas.
Freq.
2/Shift
Part
Meas.
Freq.
2/Shift
Part
Process /Part
USL
0.097
0.097
USL
UCL
0.00895
0.00895
UCL
Part/Proc Avg.
0.0874
0.0874
Part/Proc Avg.
LCL
0.0851
0.0851
LCL
LSL
0.077
0.077
LSL
Summary Example
Pp
2.54
2.5
Pp
Ppk
2.41
2.28
Ppk
INITIAL PROCESS STUDY
Quantity Attempted
30
30
Quantity Attempted
SUPPLIER CODE
MFG. LOCATION
SUPPLIER
Quantity
Accepted
30
30
Quantity
Accepted
0
0
FTC Percent (without

repairs)
100%
100%
FTC Percent (without

repairs)
1/0/1900
ACC
ACC
ACC/ REJ
% GR&R ACC/ REJ
12.70%
9.37%
% GR&R

Process Feature/Part Characteristic: The process feature or part characteristic that is being measured.
Process/Part: Document if data is for a process measurement or a part measurement.
Meas. Freq.: Measurement Frequency. Record the number of part/process measurements taken per time
interval.
USL: Upper Specification Limit. The upper limit of the part or process specification per the part drawing or
process standard.
UCL: Upper Control Limit: The upper limit established by the Supplier for process/part control.
NOTE: This number should be less than the USL.
Part/Proc. Avg.: Part/Process Average. The average of all measured process features/part characteristics.
LCL: Lower Control Limit: The lower limit established by the Supplier for process/part control.
NOTE: This number should be greater than the LSL.
LSL: Lower Specification Limit. The lower limit of the part or process specification per the part drawing or
process standard.
PP: The calculated PP for all measured process features/part characteristics.
PPK: The calculated PPK for all measured process features/part characteristics.
Quantity Attempted: The total number of part/process measurements taken.
Quantity Accepted: The total number of part/process measurements acceptable per the established
controls (within the LCL-UCL).
FTC percent (without repairs): Calculated First Time Capability. For further details, please see Appendix C.
% GR&R: Calculated percentage of Gage R&R for gage used for part/process measurement.
Acc/Reject: Has the PSO team determined the suppliers data to be acceptable (acc) or unacceptable?
[i.e. LCL <Proc Avg < UCL; PP PPK matrix requirement (see Initial Process Study element); FTC 90%;
GR&R < 10% ; 10%< GR&R < 30% PSO team decision].
65
66
COMMENTS:
CHARACTERISTIC
SPECIFICATION
(3.6 - 7.5 mm)

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

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

The MEASUREMENT SYSTEM REPORT is used to document the results of the measurement audit
performed during the PSO On-Site Visit. Use additional copies of the form or attach additional pages as
needed to accommodate more characteristics.
Number of parts witnessed: The number of parts on which the SQE has personally witnessed the supplier
measure characteristics.
Witnessed by: The names of all the Chrysler PSO team members who witnessed the measurement audit.
Characteristic: Measurement characteristics identified by the team to be measured.
Specification: The documented specification of the characteristics as identified on the part drawing.
Method of Measurement: The gage, fixture, or equipment used to measure the identified characteristics.
Quantity Attempted: The total number of parts chosen to be measured by the team (this may exceed the
number of parts witnessed by the PSO team members).
Quantity Accepted: The number of parts which whose characteristic was within the specification.
FTC percentage (without repair): Calculated FTC. For further details, please see Appendix C.
PP/PPK: The calculated PP/PPK for the quantity of parts attempted.
Process Acc/Reject: Has the PSO team determined the suppliers measurement process to be acceptable
(acc) or unacceptable (Reject)?
Comments: Any waivers/deviations should be recorded here for documentation purposes.
67
How to find the Daily Tooling Capacity and Operating Pattern

For Chrysler SQEs:
Log onto the Supplier Quality Portal at
https://gsp.extra.chrysler.com/SQP/servlet/SQPServlet
Move mouse to Summaries and click on Part Summary from the drop-down menu
Enter the part number and click on the Fetch box
Click on Part PO Details to obtain Tooling Capacity and Operating Pattern
68
APPENDIX B
Tables and Examples
69
LOT ACCEPTANCE SAMPLING TABLE
Lot Size or Shipment

Size*
Sample Size Per Characteristic Classification

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

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

Correct Process
Sort 100% since last

conforming lot
70
PERFORMANCE MATRIX
There are two risks inherent in every decision, either (1) we have accepted bad parts (consumers risk), or
(2) we have rejected good parts (producers risk). Test plans seek to balance these risks by specifying
sample size and/or acceptance criteria so that neither the consumer nor the producer carries the higher
proportion of risk.
Sometimes, for business or other reasons, it may be important to hold one risk constant and allow the other
risk to float based on sample size. Such is the case for PP and PPK. Chrysler wants to minimize its risk of
accepting a population below 1.33 PPK.
The following table presents the sample size and acceptance criteria that keeps the risk of accepting a bad
population ( 1.33) at 6.4% (93.6% that population > 1.33 PPK will be accepted). Depending upon sample
size, the risk of rejecting a good population ( 1.67) could be very high. The table allows for trade-offs
between sample size and producers risk to be identified.
Sample Size
Acceptance PPK Criteria
Risk of Accepting a
Population <= 1.33 PPK
Risk of Rejecting a
Population >= 1.67 PPK
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
150
200
250
300
2.94
2.10
1.89
1.78
1.71
1.67
1.64
1.61
1.59
1.58
1.56
1.55
1.54
1.53
1.52
1.52
1.51
1.50
1.50
1.49
1.46
1.44
1.43
1.42
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
86.3%
77.3%
68.7%
60.7%
53.3%
46.5%
40.4%
34.9%
30.1%
25.8%
22.0%
18.7%
15.9%
13.4%
11.3%
9.5%
8.0%
6.7%
5.6%
4.7%
1.9%
1.0%
0.6%
0.3%
71
1st Layer of
Management
Supervisors Supervisor 1
2nd Layer of
Management
Area
Managers
Supervisor 2
Own Department
Supervisor 3
Own Department
Area Manager 1 Own Area
Plant Staff
and Plant
Manager
Department F
1 per 1 per
shift shift
1 per 1 per
shift shift
2 per
week
2 per 2 per 2 per

week week week
2 per 2 per
week week
Area Manager 2 Own Area

3rd Layer of
Management
Department E
1 per
shift
Department D
1 per
Own Department shift
Audit
Assignment
Department C
Assigned
Management
Personnel
(example)
Department B
Assigned
Management
Category
(example)
Department A
EXAMPLE: LPA FREQUENCY AND STRUCTURE
Engrng Mgr
Rotate Depts.
1 per week
Quality Mgr
Rotate Depts.
1 per week
Tooling Mgr
Rotate Depts.
1 per week
H.R. Mgr
Rotate Depts.
1 per week
Training Coord.
Rotate Depts.
1 per week
Plant Manager
Rotate Depts.
1 per week
72
ADDITIONAL INFORMATION FOR FMEA

Severity / Occurrence Grid
10
(I)
High
Severity Zone
Severity
(II)
Potential High Warranty Zone
6
5
4
3
(III)
2
1
1
4
5
6
Occurrence
10
Special Attention Shall Be Given To:

Failure modes that have a Severity 8 regardless of RPN value, Occurrence level, or
Detection level.
Failure modes that have Severity 5 and an Occurrence 4 regardless of Detection
and RPN value. (This equates to customer dissatisfaction and Cs/1000 >1).
Detection = 10. (The potential defect is allowed to leave the plant and reach the
field).
Special Attention includes Recommended Actions and Continuous Improvement
activities as determined by the PSO Team.
Use and Purpose of the Process FMEA:
PFMEA identifies the process functions, its requirements, and documents items
that could go wrong based on historical data.
Provides feedback to the DFMEA to initiate a re-design, if necessary.
Identifies what process preventions or controls will be needed for occurrence
reduction or detection ranking reduction.
PFMEA is an assessment of potential risks of defects passing to the customer. To
mitigate these risks the following tools are used:
Error/Mistake Proofing
Process Control Plans
Preventive Maintenance Plans
73
The PFMEA drives the Error/Mistake Proofing, the Process Control Plans, and
Preventive Maintenance Plans.
Without an effective PFMEA, high risk failure modes may not be adequately
controlled.
PFMEA is not an individual assignment but a team activity.
Risk Priority Number (RPN) is a tool that can be used to ascertain robustness of the
design or the process. However, RPN thresholds are not recommended for use in
mandating corrective actions.
Corrective action items should be directed towards first reducing the occurrence of
failure modes with high Severity and/or high occurrence values, then reducing the
Detection values (see Special Attention Shall Be Given To: above).
Suppliers should use the AIAG manual Potential Failure Mode and Effects
Analysis as a reference for proper methods and procedures for developing PFMEA.
RPN = Severity of failure (S) * Likelihood of Occurrence (O) * Detection ability (D)
PFMEA TERM
Severity (S)
Occurrence (O)
Detection (D)
Risk Priority
Number (RPN)
DEFINITION
It is an assessment of the
seriousness of the effect of the
potential failure mode to the
customer. Severity applies to the
effect only.
It is how frequently the specific
failure cause/mechanism is
expected to occur.
It is an assessment of the
probability that the proposed
current process control will detect a
potential cause/mechanism, or the
probability that the process control
will detect the subsequent failure
mode, before the part or
component leaves the
manufacturing operation or
assembly location.
The team shall undertake efforts to
reduce risk through corrective
action(s). Special attention should
be given when severity is high (i.e.,
8).
RATING SCALE
1 - 10
1 - 10
1 - 10
1 - 1000
74
APPENDIX C
FTC Calculations
75
First Time Capability

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

This three-step procedure is suggested for calculating a production line FTC.
1.
2.
3.
Create a block diagram for the process showing each operation. The flow diagram or floor layout
provided by the plant can also be used.
Collect the following data from the PDR.
a. Quantity of assemblies attempted.
b. Quantity of rejected assemblies from each operation.
c. Quantity of acceptable assemblies from the end of the line. Do not include repaired or reworked parts.
Calculate the operation and process FTC using the examples as a guide.
76
First Time Capability

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

quantity attempted at the operation, 300 units. The result is the
operation FTC.
300 Pcs
FTCOp 1
30 Pcs
Rejected
Qty Completed
Qty Attempted
270
300
0.90 or 90%
Figure 1A
In a similar manner, calculate the FTC for each operation in the process using Equation 1. The
general operation model is shown in Figure 1B. Table 1 shows a summary of the quantities and
FTCs for the process in Example 1.
Quantity
Attempted
Operation
Number
Quantity
Completed
Quantity
Rejected
FTCOPERATION
Qty Completed
Qty Attempted
Equation 1
Figure 1B
77
Operation
Quantity
Attempted
Quantity
Completed
FTC
300
270
0.90
270
243
0.90
243
226
0.93
226
217
0.96
TABLE 1
Quantities and FTCs for Example 1
Enter the calculated operation FTCs in their respective operation blocks of the process diagram.
Calculate the process FTC by dividing the quantity completed for the process, 217 units, by the
quantity attempted 300 units.
Total Qty Completed 217
FTCPROCESS
0.723 or 72.3%
Total Qty Attempted 300
Enter the FTCPROCESS value on the process diagram. The completed Example 1 process diagram is
shown in Figure 2. The diagram can be included with the final PSO documents as a record of the
process starting capability.
Operation 1
FTC
90%
Operation 2
270 Pcs
FTC
90%
Operation 3
243 Pcs
FTC
93%
Operation 4
226 Pcs
FTC
96%
217 Pcs
FTC = 72.3%
300 Pcs
30 Pcs
Rejected
17 Pcs
Rejected
27 Pcs
Rejected
9 Pcs
Rejected
Figure 2
Example 1 - Series Process With Operation and Process FTC's Shown
Example 2, Series/Parallel Process Flow without Repair:

Using the three-step data collection procedure outlined on page D.2, the following processed and
rejected quantity data were collected during the PDR. The data are shown on the process diagram
in Figure 3.
Operation 3
96 Pcs
94 Pcs
2 Pcs
Rejected
Operation 1
Operation 2
288 Pcs
Operation 4
Operation 6
242 Pcs
265 Pcs
218 Pcs
91 Pcs
81 Pcs
300 Pcs
12 Pcs
Rejected
10 Pcs
Rejected
23 Pcs
Rejected
24 Pcs
Rejected
Operation 5
78 Pcs
67 Pcs
11 Pcs
Rejected
Figure 3
Example 2 - Series / Parallel Process Flow Diagram With Demonstration Data
78
Calculate the FTC for each operation in the process using Equation 1 and the operation model
shown in Figure 1B on page 2. Table 2 shows a summary of the quantities and FTCs for the
operations in Example 2.
Operation
Quantity
Attempted
Quantity
Completed
FTC
300
288
0.96
288
265
0.92
96
94
0.98
91
81
0.89
78
67
0.86
242
218
0.91
TABLE 2
Quantities and FTCs for Example 2
Enter the calculated operation FTCs in their respective blocks on the process diagram. Calculate
the process FTC by dividing the total quantity completed, 218 Units, by the quantity attempted,
300 units. The result is the FTC for the process.
FTCPROCESS
Qty Completed
Qty Attempted
218
300
0.726 or 73%
Add the process FTC to the process diagram. The completed diagram for Example 2 is shown in
Figure 4. The diagram can be included with the PDR report to document the initial process
performance.
96 Pcs
Operation 3
94 Pcs
FTC
98%
2 Pcs
Rejected
Operation 2
Operation 1
FTC
96%
288 Pcs
FTC
92%
Operation 6
Operation 4
265 Pcs
91 Pcs
FTC
89%
242 Pcs
81 Pcs
FTC
90%
218 Pcs
FTC = 72.6%
300 Pcs
12 Pcs
Rejected
10 Pcs
Rejected
23 Pcs
Rejected
78 Pcs
Operation 5
FTC
86%
24 Pcs
Rejected
67 Pcs
11 Pcs
Rejected
Figure 4
Example 2 Series / Parallel Process With Operation and Process FTCs Shown
79
80
APPENDIX D
PSO Extended Run
81
PSO Extended Run

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

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

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

circumstances.
Table 1
82
APPENDIX E
83
FOREVER REQUIREMENTS
Forever Requirements (FR) are a collective group of activities. These activities are required of all
Tier 1 Suppliers by Chrysler and must be performed in order to assure process stability and
component quality (see items 1 through 5 below).
1. Suppliers are to proactively communicate with Chrysler. Know when to raise the red
flag. This includes but is not limited to tooling refurbishment or replacements.
2. Suppliers are to request approval from Chrysler prior to implementing any anticipated
material or process changes. This includes tool and equipment moves on the suppliers
plant floor (e.g., from point "x" to point "y" within location 12345-A).
3. Suppliers are to request approval from Chrysler prior to implementing any internal
movement (between facilities e.g., 12345-A to 12345-B) or Sub-Tier manufacturing
location changes.
NOTE: Movement of any existing part number (and related tooling) between facilities,
for example 12345-A to 12345-B, are addressed via the RESOURCE PROCESS. The
resource process can only be initiated by the Chrysler Buyer. Contact the Buyer for
further instructions (see Resource Section). Sub-Tier manufacturing location changes
are addressed via the FOREVER REQUIREMENTS system.
4. Suppliers are to watch for Sub-Supplier issues and inform Chrysler of them.
5. Suppliers are to notify Chrysler of possible supply and/or capacity issues.
Once the need for a FR has been determined, the document should be processed as quickly as
possible in order to avoid manufacturing interruptions or a delay in efficiencies.
The Tier 1 Supplier shall submit the FR requests through the on-line Chrysler WebCN
Management System. Suppliers must request and receive approval from Chrysler before
implementing any of the above or related activities (see items 1 through 5 above). Electronic
approvals from Supplier Quality, Engineering, Procurement (as well as any other assigned
approvers) are required before the FR document is finalized. Completed changes must still be
PPAP-approved.
FR Risk Drivers Examples include but are not limited to:

New Technology for either the part or the process
New and/or different application(s) of a carry-over part
A part or system from a supplier with historical launch problems
New part or system with a recent major design change
Parts or system coming from a new manufacturing location
Parts or systems with recurring quality issues
84
Forever Requirement System access

Available through:
Engineering Portal (Chrysler Engineering)
Supplier Quality Portal
COVISINT (Suppliers)
Direct through intranet (using the URL noted below) on line at:
https://extranet-6.extra.chrysler.com/webcn/home.jsp
85
Supplier Initiated Forever Requirement Process Flow

Supplier recognizes
they need to make a
change.
Supplier Login GSP

to initiate Change
Request.
FR Change Request
document is created
Originator Submit
Document
Header View contains enough information to

receive Document number.
Supplier Quality enters

Risk Assessment data )
Header view
System moves
document to
Ready for
Approval
This must be done before

any approval can happen!
Approval Process
Begins (sign-off)
Team reviews -Approves,

(LVL 1)
More info or rejects
Buyer Approves
System (LVL 2)
System moves
document to
Finalized
Document is frozen from next Sequence Level of

approver if: Rejected or More info selected.
Note: All LVL 1 must approve before LVL 2 can!
New Location
Authorized
STATUS
Document is
Electronically
Finalizes
Assigned
Submit
Ready for Approval
Prod. Control sets

In/Out Effective
Points
Logistics creates
new route
Chrysler Plant(s)
Notified
Finalized
1. The Supplier determines that an FR-related change is necessary.

2. Supplier enters the COVISINT and fills out the Header Page to initiate a Forever Requirement.
3. FR documents should be created a minimum of three (3) months before the planned change(s)
or proposed implementation date(s) are required by Chrysler.
4. Supplier submits completed Forever Requirements for approval. NOTE: if the change(s) affect
multiple platforms, the Supplier must ensure that all of the appropriate Release Engineers are
added to the team list.
5. The SQE, a level one (LVL 1) approver, begins the approval process by risking the FR
document on the Header page.
6. The remaining (LVL 1) approvers review the FR for compliance with the needs of their
respective organizations (i.e., approving or rejecting the document in line with their specific
requirements).
7. The Team may provide quick approval, or additional information may be required by the level
zero (LVL 0) and/or (LVL 1) approvers. The document receives its final approval from the level
two (LVL 2) approver (i.e., the Chrysler Buyer).
8. Once the FR request is approved, the document is moved into finalized status by the system.
9. After the FR is approved, the Supplier assures that any and all remaining tasks are completed.
These tasks will include, but are not limited to PER, PSO, and PPAP.
86
NOTE: if the requested change(s) was rejected by any of the approvers, the Supplier must correct
the rejected item(s) and resubmit the document to the Team. Failure to resubmit the document
will end the Forever Requirements process for the proposed change(s). Additionally, if the rejected
change(s) cannot be corrected the document is cancelled. The approval (or rejection) process
should be concluded by all affected Chrysler personnel within 5 business days.
Issues related to ODD Box items should be addressed by including detailed attachments of the
concern to the FR Document.
A fully approved Web CN FR indicates that Chrysler approves the plan only (as additional tasks
may be required). Suppliers will distribute hard copies and/or electronic notifications of
completed tasks as necessary.
Forever Requirements Non-conformance Violations System:

This system is utilized to document a Supplier's lack of compliance with the Forever Requirements
Process. The procedures associated with this system allow the SQE to locate, track, and support
appropriate resolution of the respective violation(s).
The SQE has responsibility for management of the Forever Requirements Violation Process.
The responsible SQE (Originator) investigates the potential Forever Requirements Violation and
determines if it falls within the following categories:
Process change, Change to construction or material,
Parts produced at different / additional locations
Sub-supplier location change
Sub-supplier material change
Tooling capacity change
Unauthorized tooling transfer
Unauthorized refurbishment / replacement
Supplier submitted Forever Requirements request, but implemented the change
before receiving approval from Chrysler
Other
For additional information refer to the supporting BoK procedure Forever Requirements
Violation. Suppliers do not have access to this system and should contact their Chrysler SQE for
additional information.
Resourcing clarification:
Resourcing is a process that includes the occurrence of any activity noted below. These events
may take place prior to, or during volume production.
1.
2.
3.
4.
Movement from an existing supplier to a new parent supplier

Shipping Point location change within the same 5 digit supplier code
Manufacturing location change within the same 5 digit supplier code
Division change, within the same Top Parent (including new 5 digit supplier code in the
same manufacturing location)
5. Percent of Business Allocation change
87
The Buyer initiates a Resource Notice for any of the above examples through the WebCN
Management System. Electronic approvals from Quality, Engineering, Logistics and
Material Handling are required before the Resource Notice document is approved.
NOTE: If an activity listed above is initiated by a Tier 1 Supplier, that request must be
submitted to the Chrysler Buyer through a formal letter or e-mail. The Buyer will then
evaluate the request and initiate the Resource Notice. Completed changes must still be
PPAP approved.
For additional information on Resourcing activities, process flowcharts etc., the SQE should refer
to the Book of Knowledge (BoK). Suppliers do not have access to this system and should contact
their Chrysler SQE for additional information.
88
APPENDIX F
Chrysler Internal PSO Requirements
89
Internal Powertrain PSO

3 Steps to Approval
PV
Testing
Production
Demonstration Run
(PDR) & Analysis
Documentation
90
Internal Powertrain PSO

Documentation
The following documentation will be supplied for final PSO approval by the following Chrysler groups:
Product Engineering, Advanced Manufacturing Engineering, and the internal Powertrain Plant.
Product Engineering
Release Part Prints w/ Change Verification/ Level Identified
CATIA comments sheet (list of Engineering standards on sheet)
A copy of applicable performance, process and material standards (PF Standards)
Engineerings procedure for documentation revision changes due to part number changes
Engineerings procedure for obtaining and distributing CATIA revisions
DFMEA
Internal best practice document for DFMEA development
DVP&R (Chrysler Engineering signed DV test plan, Chrysler Engineering signed completed DVP&R
for DV testing, Chrysler Engineering signed PV test plan)
Documented waivers for any testing
Engineering MQAS procedure for Problem Solving
Supplier definition of and internal requirements for special product and process characteristics
Chrysler Engineering signed DVP&R for PV test results (MANDATORY ENGLISH DOCUMENT)
PV test procedures (MANDATORY ENGLISH DOCUMENT)
Chrysler Engineering approved BSR results (if applicable) (MANDATORY ENGLISH
DOCUMENT)
Advanced Manufacturing Engineering
AMEs procedure for documentation revision changes due to part number changes
PFMEA (MANDATORY ENGLISH DOCUMENT)
Internal best practice document for PFMEA development
Process Flow Diagram (MANDATORY ENGLISH DOCUMENT)
Manufacturing floor plan
Work Station Layout
Dimensional Control Plan
Best Practice document for developing Control plans (input from FMEA & Control plans for similar
products)
Authorization to Ship (ATS Package)-Equipment Qualification at the Plant
AME MQAS procedure for Problem Solving
Tooling List
91
Tool Layouts
Assembly Graphics
Tool & Op Sheets
Spare Parts List
Error and mistake proofing plan. This includes a list of error and mistake proofing by operation
number
Line Speed Simulation
AME MQAS procedure for gauge identification
PM plan, schedule, procedure and work instructions
Plant Deliverables
Plants procedure for documentation revision changes due to part number changes
Plants procedure for obtaining and distributing CATIA revisions
Control Plan (MANDATORY ENGLISH DOCUMENT)
Best Practice document for developing Control plans (input from FMEA & Control plans for similar
products)
PPAP status list
Plant MQAS procedure for Problem Solving
Incoming inspection plan and procedures
Incoming sampling plans
Receiving reports
Material standards
Inspection/test reports
Parts Handling Plan
Material Handling procedures
Packaging Instructions
Maintenance plan for WIP (work in process) containers
Copy of Routing cards or travelers
Operator, 1st piece approval, mistake proofing, set-up, changeover, rework/repair, inspection and
packaging instructions
Record of operator training
Operator qualification process
Documentation control procedure
Visual management (displays & diagrams)
First Production Shipment Certification (FPSC) Plan (MANDATORY ENGLISH DOCUMENT)
Control Charts (As Applicable)
92
Process Performance Charts (As Applicable)

Total Production Maintenance charts
Error and mistake proofing studies
Mistake Proofing Contingency Plan (in the event mistake proofing becomes inoperable)
Log Sheets
Defect Tracking Sheets
Corrective Action Forms
1st Piece Approval Procedure & Records
Measurement System Verification Report (MANDATORY ENGLISH DOCUMENT)
Line Speed section on Production Demonstration Results form (MANDATORY ENGLISH
DOCUMENT)
Documented deviation to the 300 part or 2 hour requirement (if applicable)
Process Constraints (bottlenecks) documented on PSO COMMENTS SHEET
Final Audit Plan
Final Audit Procedure
Final Audit Work Instructions
Part Inspection Standard (if applicable) - (MANDATORY ENGLISH DOCUMENT)
Final Audit Sampling plan
Shipping Record Example
Audit Record Example
Containment Record Example
Parts Packaging and Shipping Plan
Packaging and Shipping Procedures
Packaging, shipping and labeling instructions
Returnable Container Management Plan
Barcode Labeling Procedure
Shipping Label example
Plant MQAS procedure for gauge identification
Gage Plan
Gage R&R results (MANDATORY ENGLISH DOCUMENT)
Gage and Test Equipment Calibration Records and validation plan
Calibration Schedule & reaction plan
Initial Process Study results (on Production Demonstration Results form) (MANDATORY
ENGLISH DOCUMENT)
93
Deviations to Initial Process Study requirements documented on the PSO COMMENTS SHEET (if
applicable) (MANDATORY ENGLISH DOCUMENT)
Deviation from FTC requirement w/Commodity Supplier Quality Manager signature (if applicable)
(MANDATORY ENGLISH DOCUMENT)
Simulation or shipping test results (Corp Mat Handling)
Warranty process flow diagram (MANDATORY ENGLISH DOCUMENT)
Warranty procedures
Annual Validation Schedule
Production Demonstration Run & Analysis

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

To assure that all Internal Powertrain PSO requirements have been met, the Internal Powertrain Process Signoff Package should include the following documents
Internal Powertrain Process Sign-off form along with the deviations list. The sign-off form should
include all necessary signatures.
The Internal Powertrain PSO work sheet.
Production Demonstration Run (PDR) Results Form. (This is a standard PSO document titled Line
Speed Demonstration Results Form)
94
FREQUENTLY ASKED QUESTIONS

Please check https://gsp.extra.chrysler.com/qlty/pso/index.html for the most current
version of the FAQ.
95
1.
How far down do we go with the certification of the supply chain? 3rd tier? 4th tier?
Certification down to the production material Suppliers and, if applicable, any secondary
processes/services (e.g. plating, heat treating, etc) would be sufficient.
2.
What should our reaction plan be if Suppliers refuse to conduct PSO's on their sub-tier
Suppliers?
PSO is part of Chrysler's Supplier evaluation and the Production Part Approval Process.
According to TS-16949 and the Chrysler Customer-Specific Requirements for TS-16949,
Suppliers are responsible for evaluation and Production Part Approval of their sub-tiers. All
Chrysler Suppliers are required to be TS-16949 3rd Party certified. Note that while this does
not require that Suppliers perform a PSO specifically, it does require an evaluation and/or
PSO-like activity. Failure to conduct evaluations and Production Part Approval of sub-tiers is
a failure to meet TS-16949 requirements and may result in the loss of Chrysler business.
Notify the Buyer and Global Sourcing Management of any occurrence of this situation.
3.
Suppliers don't follow the Lot Acceptance Sampling Table. They always inspect about 5
parts/lot; lot size is 1,000 pcs. Should we force them to inspect as many as the table says?
For attribute sampling, two or more of the inspection criteria in TS-16949 shall be used,
otherwise the guidelines in the Lot Acceptance Sampling Table shall be followed. For variable
sampling, the Supplier shall be consistent with the Statistical Process Control manual
requirements.
4.
Medium- and High-risked parts require a PSO led by the Chrysler SQE. If the PSO Team
considers a product to be Low risk, is PSO required?
Yes. All Low-risk products shall have a Supplier led PSO that documents and establishes
their production readiness.
All High-risked products will have both a Chrysler led AQP and PSO. All Medium-risked
products will have a Chrysler led PSO and a Supplier led APQP.
5.
If a Supplier changes a process, where does the Supplier go to start the PSO process, the
Responsible Design Engineer or the SQE? We've been told both.
Before a Supplier makes any changes to their assembly process they shall initiate a Forever
Requirements request and obtain approval from the Chrysler Release Engineer, SQE, and
Buyer. The SQE will determine the risk level of the change (if approved).
6.
Most Suppliers use CMM printout for inspection documentation. Do we need to transfer this
data to the appropriate form?
No, a copy can be attached or a statement provided on the Comments Sheet that the PSO
Team verified the measurement.
7.
In a multi-cavity tool, should parts come from all cavities to calculate capability or
performance indices (i.e., CP/CPK and PP/PPK)?
Parts should come from all cavities, however each cavity (process stream) should be
calculated individually as stated in the Statistical Process Control (SPC) manual.
96
8.
Our forms do not have a control number or issue date. This is an ISO/TS-16949 requirement.
What should be done?
The forms are part of the manual, and they are identified in Chryslers Master Record List.
9.
Why don't we take rework into account when calculating FTC?

Greater quantities of rejects increase the potential for greater quantities of nonconforming
parts shipped. Chrysler PSO Teams will review FTC at each Supplier to confirm that defects
have been minimized. If rework were included in the calculation, it wouldn't be a measure of
actual First Time Capability. While we recognize that rework of in-process rejects is common,
we want to measure the true First Time Capability of the process in order to quantify the
quality potential.
Appendix C provides a standard method and examples for calculating FTC for a new process
with no rework.
10.
Can the PSO Team accept a Production Demonstration Run which is less than 300 pieces/2
hours?
Yes. The PSO Team shall authorize any deviation from requirements (minimum of two hours
or 300 pieces, whichever is more stringent) and enter an explanation on the PSO Comments
Sheet.
11.
Clarify IAA requirements.

An IAA is required whenever the Supplier has to ship non-PPAP parts to Chrysler or a
Chrysler-designated manufacturing facility after the required quality gate. It is required even
if PSO A or Z approval has been given, but PPAP has not been submitted. IAAs are also
required when temporary changes are made to the part and/or process (e.g. temporary
rework, repairs, temporary operations, etc.). Contact your Chrysler SQE or Product Engineer
for additional information, including which quality gates require an IAA for non-PPAP parts.
12.
You don't have to have PSO approval prior to V1 if you have an IAA. Explain the system of
tool payment after PSO elements 1-20 without an approved PSW.
IAA is not an alternative to PSO. An IAA indicates failure to meet program requirements. It
enables shipments on an interim basis to support vehicle development timing until corrective
action (PSO approval) can be completed.
After a Supplier successfully completes the first 20 elements for both documentation and
process, the SQE grants a Z disposition which, following the submission of a dimensional
warrant, allows tool payment at the discretion of the Purchasing Agent.
13.
Who gets the FPSC form in the plant? Is there an organization to handle this?
The Supplier shall review the plan and Gate C - S1 Start results with the PSO Team at the
Pre-PSO meeting. All FPSC results shall be retained by the Supplier for 1 year after V1
Launch for review by Chrysler personnel upon request.
97
14.
Regarding FPSC, what if we take a truck frame with 400 dimensions, for example. How many
frames do we need to measure? All 2000?
The AQP Team, working with the Supplier, will determine what shall be an adequate plan to
satisfy the FPSC requirements.
15.
Expand the FPSC explanation. Add examples for attendees to follow. Include a slide that
explains a statistical analysis of the first 2,000 pieces is required which is different than the
300 piece PSO capability study.
Parts from the SRE and PDR runs are generally not included in FPSC duration (although
they still must be inspected per the FPSC plan). However, the AQP/PSO Team may allow
them to be included in certain situations, especially if some of these parts will be used for
production. Refer to the internal Chrysler First Production Shipment Certification (FPSC)
process in BoK and on the PSO website.
16.
If an offshore Chrysler employee performs a PSO in his/her local country, this manual
requires them to use English for the master documentation. This should be a team decision.
Chrysler is a global company. As stated, English is the official language of Chrysler and
therefore an English translation has to be available. It does not preclude other language
versions.
17. Who pays for additional manpower needed to support FPSC?

FPSC is an AQP/PSO requirement and any additional manpower or tooling needed to fulfill
this requirement is the sole responsibility of the Supplier.
18.
At what level must packaging be signed off?

Supplier designed packaging shall be signed off by Chrysler Corporate and the receiving
Assembly Plant Material Handling Engineering prior to Z approval of the PSO using the Unit
Load Data (ULD) sheet (available in the Chrysler Packaging and Shipping Instructions
manual). Actual packaging shipping testing shall be signed off by Chrysler Assembly Plant
Material Handling Engineering prior to PSO A approval. Packaging shipping simulation
testing shall be signed off by Corporate Material Handling Engineering prior to PSO A
approval. For Chrysler designed packaging, PSO approval must not be delayed due to a
lack of approval(s). Any questions concerning approval of Chrysler-designed packaging
should be referred to the Chrysler Material Handling Group.
19.
Is it acceptable for a Supplier to add or remove operators from a production line during the
line speed demonstration?
The number of operators required for the production line shall be identified on the Process
Flow Chart, Manufacturing Layout, and/or Workstation Layout. The Supplier may not
deviate from this number during the PDR; line-balancing and other ergonomic or efficiency
studies are expected to be completed prior to the PSO On-Site visit.
98
20.
If a reference characteristic is showing out-of-specification on the Initial Process Study, should

I approve the PSO?
This depends on what is meant by a reference characteristic. Strictly speaking, a reference
dimension does not have a tolerance and, therefore, cannot be out-of-specification. Basic
dimensions, on the other hand, do have tolerances (even though they are theoretically
exact). Their tolerances are generally shown through feature control frames, drawing notes,
or other specified documents; if they are out-of-specification, then the PSO must be rejected.
All dimensions on the design model must meet and be capable to Chrysler specifications,
even those not regularly monitored.
21.
The Supplier has several required documents that they consider proprietary, and will not allow
us to review them. How do we handle this?
All AQP and PSO required documents shall be available for review at the request of the
Chrysler SQE. Review of the documents may take place at the Suppliers location or at a
Chrysler location, at the discretion of the team. In those rare cases when a Supplier refuses
to allow Chrysler personnel to review required documents at all, the PSO should be rejected
and the matter brought up to Chrysler management (SQE, Engineering, and/or Purchasing,
as appropriate).
22.
Since the new station cycle time/FTC metric is required to be completed by Gate C S1
Start, does this mean the SRE is also required by S1 Start?
No. While it makes sense to do both together (if possible), SRE is only required to be
completed before the Pre-PSO meeting and may be done after S1 Start.
99
REFERENCE MANUALS
Chrysler Manuals:
Packaging and Shipping Instructions
Product Assurance Testing
Test Data Analysis manual
P&S 8-Step Corrective Action Process manual
Available From:
Lanier Professional Services

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

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

Phone No: (248) 358-3003
www.aiag.org
Chrysler personnel can obtain copies of Chrysler manuals through eCopier on

DashboardAnywhere.
100
GLOSSARY
101
AUTOMOTIVE INDUSTRY ACTION GROUP (AIAG): a group founded in 1982 by

representatives from Chrysler, Ford, and General Motors. The purpose of the AIAG is to
provide an open forum where members cooperate in developing and promoting solutions
that enhance the prosperity of the automotive industry. AIAG's focus is to continuously
improve business processes and practices involving trading partners throughout the
supply chain. The AIAG website is at http://www.aiag.org.
BOUNDARY SAMPLES: part samples created as an inspection aid. Samples are typically
created at the specification limits (e.g. go and no-go) or at the worst-possible
acceptable condition (e.g. no worse than). Boundary samples must be clearly marked
and/or identified to prevent shipment to the customer and properly controlled to prevent
degradation and ensure relevance.
BUZZ SQUEAK RATTLE (BSR): objectionable vehicle noise attributes. All BSR issues
are tracked by Vehicle Development and subsequently assigned to the most responsible
party for resolution, be it Engineering, Manufacturing, or the Supplier. Although
somewhat subjective, eliminating BSR issues leads to higher customer satisfaction.
CAPABILITY STUDY: is a statistical analysis of the output from a machine or a process to
determine its ability to produce product that meets specifications. This analysis is
especially important when a new product is introduced so product quality and variation
reduction can be assessed.
CATIA: is a computer-aided, three-dimensional interactive application design and
manufacturing system. This software was developed and is maintained by Dassault
Systemes of France and is marketed in the United States by IBM. It is known as a
CAD/CAM system.
CHRYSLER DEVELOPMENT SYSTEM (CDS): CDS provides a framework for a total
systems approach to Product Creation. This framework shortens the overall time for the
development and launch of a vehicle, while providing a communication forum.
Consistency among product teams is achieved by using a standard process. CDS keeps
the design window open for a longer period to ensure products meet or exceed external
requirements. At the same time, it ensures that the design and feasibility for both product
and process is complete prior to execution. By completing design and feasibility prior to
execution, using virtual design tools, costly changes are eliminated in the execution and
launch phase. The CDS website is at http://roadmap.tcc.chrysler.com/cds/.
CONTINUING CONFORMANCE TESTING (CC): tests and evaluations performed after
production launch to monitor the effects of processing and to assure continued
conformance to engineering requirements. CC testing is typically documented on the
Control Plan and/or DVP&R.
CONTROL PLANS: written descriptions of the systems for controlling parts and processes.
They are written to address the important characteristics and engineering requirements of
the product. Each part is required to have a Control Plan, but in many cases, family
Control Plans can cover a number of parts produced using a common process. Customer
approval of Control Plans may be required prior to production part submission.
COVISINT: A web based system that grants qualified Supplier users access to selected
portions of the Chrysler Network.
102
CP: capability index that compares the process capability to the maximum allowable
variation as indicated by the tolerance. This index provides a measure of how well the
process will satisfy the variability requirements. CP is not impacted by process location.
This index can be calculated only for two-sided (bilateral) tolerances. (Statistical Process
Control Manual, pg. 132)
CP=
USL - LSL
6 C
Where,
USL LSL
6 R
d2
USL = Upper Specification Limit

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

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

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

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

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

= A divisor of R used to estimate the process standard deviation (see the
Statistical Process Control Manual (AIAG) Appendix E.
CUSTOMER SATISFACTION AUDIT (CSA): a comprehensive review of a vehicles quality

as it leaves the assembly plant. The CSA provides a reliable indicator of vehicle quality.
DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA): formalized method for
quantifying the risk associated with identified potential design failure modes. It is used to
identify corrective actions required to prevent failures from reaching the customer. The
103
DFMEA is a living document that is updated as the design changes and progresses
through design verification and production.
DESIGN OF EXPERIMENTS (DOE): a statistical approach to efficiently plan and structure
a series of controlled tests. In its broadest sense, it encompasses planning, setting up,
running the tests, and analyzing the data. The goal is to identify the sources of product
variation that should be optimized or eliminated for consistent product performance with
a minimum number of tests.
DESIGN VERIFICATION PLAN AND REPORT (DVP&R): formalized test planning and
reporting tool. It lists the testing necessary to assure that functional and reliability
criteria and target requirements are defined in specific measurable terms. It provides a
convenient reporting format for Engineering Development (ED), Design Verification (DV),
Production Validation (PV) and Continuing Conformance (CC) testing.
DESIGN VERIFICATION (DV) TESTING: testing phase that demonstrates the final
released component or assembly meets design intent. The tests, sample sizes, and
performance requirements are detailed in Engineering Performance Standards.
DRAWING CHANGE LEVEL: the latest design level of the released drawing. It is a two
digit alpha field that can be accessed on ODCICS2 through screen ENAA or ENJA.
ELECTRONIC CORPORATE ISSUE MANAGEMENT SYSTEM (eCIMS): Chryslers
electronic system for documenting serious issues that arise during vehicle prototype,
launch, or volume production phases.
ENGINEERING STANDARDS: are written requirements that describe materials,
processes, performance, reliability, quality and/or design requirements for a material,
process, or part or a family of materials, parts, or systems.
ENGINEERING STANDARDS SUPPLIER DISTRIBUTION (ESSD): the Chrysler computer
system that gives Suppliers access to Chrysler Engineering Standards. It is available online at https://essd.extra.chrysler.com/ESSD/Login.jsp.
ERROR PROOFING: Error proofing is a method used to identify potential process errors
and either designs them out of the product or process, or eliminate the possibility that the
error could produce a defect. Examples of error proofing include:
A rod clip designed to work in left- and right-handed parts (as opposed to separate
clips for each;
A hole or slot designed so that mating parts can only fit in the proper orientation;
An operation that will not function until all components are present in the proper
orientation.
FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC): FPSC ensures that initial
production shipments meet all Chrysler product specifications. It is intended to identify
part problems and contain the parts at the Suppliers manufacturing facility during the
launch phase. FPSC requires the Supplier to provide statistical evidence of conformance
to special product and/or process characteristics prior to the shipment of components to
the Chrysler (or Chrysler -designated) assembly plant. Certification is for a minimum of
2000 parts (per assembly plant) or for a specified period of time as identified by the
Chrysler AQP team.
104
FIRST TIME CAPABILITY (FTC): FTC is equal to the number of acceptable parts
produced divided by the total number of parts produced. Rework and repair are NOT
counted in the number of acceptable parts, nor are parts initially rejected by the process
but found to be acceptable after re-testing. See Appendix C for examples.
GAGE REPEATABILITY & REPRODUCIBILITY (R&R): a method used to determine the
acceptability of a measurement system as a percentage of the product tolerance or
process variation. Repeatability is a measure of the ability of the gage to repeat a given
measurement, and is evaluated by repeatedly measuring the same parts (equipment
variation). Reproducibility is a measure of the ability of people to reproduce a series of
measurements using the same gage, and is evaluated by two or more operators
independently repeating the inspection of a set of parts (appraiser variation).
GEOMETRIC DIMENSIONING & TOLERANCING (GD&T): a system of symbols used to
define part and part feature shape, size, position, tolerances, etc.
HOME LINE: Suppliers assembly line located in the manufacturing facility where volume
production of the part(s) takes place using production tooling and processes.
INTERIM APPROVAL AUTHORIZATION (IAA): documentation and approval to temporarily
use a part that does not meet PPAP approval requirements for Pilot builds, launch, or
production.
ISO/TS 16949: is a Technical Specification that describes, in conjunction with ISO
9001:1994, the Quality System Requirements for Automotive Suppliers. ISO/TS 16949
has been prepared by the International Automotive Task Force (IATF) for all participating
worldwide OEMs.
KEY <D> CHARACTERISTICS: designated by the or <D> symbols on Engineering
Source Documents. Key Product Characteristics are toleranced and measurable
characteristics (i.e. dimensions, torque etc.) of a part, component or assembly that may
cause failure to meet customer satisfaction specifications due to manufacturing and/or
assembly, and therefore, require special attention to ensure acceptable results. Reference
PS-7300 Key Product Characteristics the Use of Diamonds for additional information.
KEY PERSONNEL: all personnel necessary for the successful operation of a production
manufacturing process during the scheduled operating pattern (as detailed on the P.O.).
This may include, but is not limited to: operators, inspectors, material handlers, process
set-up personnel, supervisors, and also management (if applicable).
LINE SPEED: the contracted maximum tool capacity rate determined by dividing the
Daily Chrysler Tooling Capacity (Pieces per Hour) by the Suppliers Net Operating Time for
Chrysler Parts (Hours/Day). The line speed shall be verified during the Production
Demonstration Run.
LOT: specific amount of material or group of components; not to exceed eight hours or
one days production, whichever is smaller.
MANUFACTURING FLOOR PLAN: a pictorial layout of the entire manufacturing facility
drawn to scale. It is to include all machinery, office space, lab space, shipping-receiving
105
areas, quarantine areas, hold areas, etc. The layout also indicates any proposed areas for
expansion and development.
MISTAKE PROOFING: Mistake proofing is a method used to clearly identify errors that
may occur and prevent them from becoming non-conformances. Examples of mistake
proofing include:
Sensors, optics, and/or vision systems that detect missing or incorrectly-assembled
components;
End-of-line (EOL) testers that check functional requirements;
Pick lights or barcode labeling to assist in proper part selection;
Continuity testing for electrical components.
NET OPERATING TIME FOR CHRYSLER PARTS: equal to the number of hours (normal
work pattern), less scheduled down-time (e.g. breaks, start up, preventive maintenance,
shared production, tool changeovers, shut-down, etc.) and time scheduled to run other
customers parts and/or other Chrysler parts.
NOISE VIBRATION HARSHNESS (NVH): measurable perceptions of vehicle attributes.
These items are usually discovered and measured by Chryslers NVH laboratory facilities.
NVH attributes are typically tuned to a certain frequency and amplitude in order to
achieve an overall vehicle signature frequency. This signature is optimized by vehicle
development for the best customer responses.
NON-CONFORMANCE TRACKING (NCT) SYSTEM: Chryslers electronic system for
documenting and tracking part issues at the manufacturing plants. It also provides a
method for replacement of those parts and for Supplier dispute of the issue. Serious
quality issues are also documented in the e-CIMS system.
OPERATOR INSTRUCTIONS: lists of steps in performing an operation that may contain
inspection requirements, required tools and gages, SPC applications, sample size and
frequency, and acceptance/rejection criteria. They communicate all requirements involved
in that particular operation and are readily accessible to the operator.
PACKAGING: material that is used to store and ship parts. It provides protection and
containment of parts. It affects ease of handling by manual or mechanical means.
Packaging may consist of returnable or non-returnable items including dunnage.
PART CHANGE LEVEL (PCL): the latest design level of the part (not necessarily the
drawing). It is a two digit alpha field found on ODCICS2 through screens ECCE or ENCZ.
PART SUBMISSION WARRANT (PSW): an industry-standard document required for all
newly-tooled or revised products in which the Supplier confirms that inspections and
tests on production parts show conformance to customer requirements.
PERISHABLE TOOLS: tools which are consumed in the process of producing a product,
and are usually a cost item, e.g., drill bits, cutters, sockets, driver tips, inserts, hobs,
broaches, welding tips, etc.
106
PP: performance index that compares the process performance to the maximum allowable
variation as indicated by the tolerance. This index provides a measure of how well the
process will satisfy the variability requirements. PP is not impacted by process location.
(Statistical Process Control Manual, pg. 133)
PP =
USL - LSL
6 P
Where,
USL LSL
6s

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

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

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

= Estimate of the standard deviation of a stable process using the sample
standard deviation of a set of individuals about the average of the set.
= Sample standard deviation for subgroups or processes; see the Statistical
Process Control manual, Chapter II, Section C or Chapter IV, Section A.
PRE-PSO MEETING: a meeting conducted by the PSO Team, chaired and coordinated by
the SQE, with the Supplier. The meeting is conducted at a Chrysler-selected location prior
to the PSO On-Site visit. The purpose is to review all of the Suppliers required
documentation in a sequential way and determine the Suppliers readiness for the
Production Demonstration Run (300 pcs.) and PSO On-Site Visit.
PRE-PRODUCTION SAMPLE REPORT (PPSR): a dimensional and performance verification
document, submitted with all part samples used prior to S1 Start.
PREVENTIVE MAINTENANCE (PM): a planned system of actions performed to prevent
breakdown of a machine or equipment as a result of normal use.
107
PROCESS CAPABILITY: the 6 C range of inherent variation in a stable process. Reference

the Statistical Process Control AIAG manual for more information.
PROCESS CHARACTERISTIC: Identified characteristics which, when controlled, reduce
variation in product characteristics. Example: pressure, temperature, force, feed rate,
RPM (torque), etc.
PROCESS PERFORMANCE: the 6 P range of total process variation. Reference the
Statistical Process Control AIAG manual for more information.
PROCESS FAILURE MODE & EFFECTS ANALYSIS (PFMEA): a structured method of
documenting historical or potential process failure modes, their effects, and the controls
taken to ensure their detection and/or prevention. The PFMEA rating system allows
quantification of the risk presented by each failure mode. The PFMEA is developed by a
cross-functional team and is uniquely developed for each process/product.
PROCESS FLOW DIAGRAM: chart that illustrates the flow of materials through the
process. The diagram generally starts at receiving and includes work in process,
production, shipping (including any special processing which may result from a
nonconformance requiring disposition), and rework or repair operations.
PROCESS SIGN-OFF (PSO) ON-SITE VISIT: a systematic and sequential review of the
Suppliers manufacturing process conducted by a PSO Team at the Suppliers production
facilities. The SQE is responsible for leading the PSO On-Site Visit for High- and Mediumrisk programs; the Supplier leads their own for Low-risk programs.
PRODUCT CHARACTERISTICS: Physical properties or distinguishing features of a part or
component, typically specified by design. Examples: length, width, tensile strength,
torque, weld integrity, color, alignment, etc.
PRODUCTION DEMONSTRATION RUN (PDR): a production run conducted during the
PSO On-Site Visit consisting of at least 300 parts or 2 hours of production (whichever is
more stringent). The PDR is on the production line of record, with trained operators, PPAP
(or equivalent) approved components and materials, and run at a rate equal to the daily
maximum tooling capacity. The Chrysler PSO Team will be on the manufacturing floor
during the PDR for all High- and Medium-risk programs.
PRODUCTION PART APPROVAL PROCESS (PPAP): process for ensuring that production
parts are manufactured that meet customer requirements. Parts for PPAP shall be taken
from a significant production run. Chrysler requires that this run is a minimum of two
(2) hours or 300 pieces, whichever is more stringent, unless otherwise stated in writing by
the customer. Parts from each position of a multiple cavity die, mold, tool or pattern are
to be measured and representative parts tested. Reference the PPAP 4th Edition AIAG
manual and the Chrysler Customer-Specific Requirements for the PPAP 4th Edition for
more information.
PRODUCT SPECIFICATIONS: all engineering drawing requirements including standards
referenced on those drawings and within the pre-source package. Some of these
requirements are determined by team consensus during Advanced Quality Planning
meetings and Design Reviews and can take the form of Safety Standards, Material
108
Standards, SRPCs, Temporary Standards, Process Standards, Laboratory Standards,

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

or <S> symbols on Engineering
Source Documents. They are product characteristics or manufacturing process
parameters which can affect safety or compliance with government regulations. See PFSAFETY Product Safety Use of Safety Shields <S> for more information.
SAMPLING PLAN: plan that defines the minimum number of parts that shall be inspected
from a given population (see the Lot Acceptance Sampling Table Plan in Appendix B).
SEQUENTIAL SENSING: type of sensor that detects if a series of operations are
performed in the correct order. Example: A station requires that an assembly receives a
screw, washer, and nut (in that order). A sequential sensor would detect and flag
(through lights, station lock-out, etc.) if the nut was put on before the washer.
SPECIAL CHARACTERISTICS: product characteristics or manufacturing process
parameters which can affect safety or compliance with regulations, fit, function,
performance or subsequent processing of product. They include all governmental, Key
(diamond) <D>, emissions <E>, safety (shield) <S>, torque requirements, and
characteristics identified as SPC points on the design model. See PS-7300 - Key Product
109
Characteristics the Use of Diamonds for more information regarding Key characteristics
and PF-SAFETY for additional information regarding Safety characteristics.
STATION CYCLE TIME: the amount of time required for one station of a production
process to complete all required operations once (i.e. from one particular event until that
event is repeated). The required operations are generally documented in the operator
work instructions for that station.
STATISTICAL CONTROL: the condition describing a process from which special causes of
variation have been eliminated. Only common causes remain; e.g., observed variation
could be attributed to chance causes. On a control chart, statistical control is evident by
the absence of points beyond the control limits and by the absence of non-random
patterns or trends within the control limits.
STATISTICAL PROBLEM SOLVING (SPS): the organized use of special problem solving
tools (e.g. Fishbone Diagrams, Pareto Charts, ANOVA, etc.), to better understand
problems, their root causes and determine solutions.
STATISTICAL PROCESS CONTROL (SPC): the use of statistical techniques such as
control charts to analyze a process or its outputs to take appropriate actions to achieve
and maintain a state of statistical control and to improve the process capability.
SUB-COMPONENT: one or more parts that when assembled together results in the EndItem Assembly or module.
SUB-TIER SUPPLIER: see TIER 2 (& LOWER) SUPPLIER.
SUPPLIER READINESS EVALUATION (SRE) RUN: the first documented build attempt by
the Supplier following installation, setup, and tryout of the production equipment and
tools. The Supplier Readiness Evaluation run shows that the process is set-up, debugged,
and ready for a Production Demonstration Run during the PSO On-Site Visit. The
Supplier Readiness Evaluation Run and analysis provides the Supplier with the
opportunity to optimize and refine the process. The Supplier, with the concurrence of the
Chrysler PSO Team, will determine the quantity of parts that are completed during this
run. The purpose of the SRE is to provide pre-production data that confirms the proper
set-up, operation, and performance of the installed production line. Data collected during
this run typically include measurement data, machine cycle times, operation times,
quantity attempted, quantity accepted, etc. From this data, estimated production rates,
FTC, yields, and PP and PPK for special characteristics are calculated. The Chrysler PSO
Team will evaluate the data from this run when deciding whether to schedule the PSO
On-Site Visit.
SUPPLIER TOOL RECORD (STR): A form generated by the creation of a new TPO (Tool
Purchase Order) requiring the identification of Supplier, or Chrysler owned tooling,
affected by the TPO.
SUPPLY CHAIN: includes all Suppliers used in producing a given part; from tier one to
the source of production materials.
110
SUPPLY CHAIN MAPPING: a method used to look at the complexity of the extended
enterprise value chain. Mapping details the manufacturing process, transportation and
other factors that go into component production.
TAKT TIME: The time in which one vehicle, assembly, or part (the item of interest) is to
be made.
TAKT Time
Net Operating Time Per Shift

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

raw material directly to Chrysler. All references to Supplier in this manual refer to a
Tier 1 Supplier, unless otherwise specified. Note that in the case of some modules, the
Supplier of a module component may be treated as a Tier 1 Supplier, even though they do
not ship directly to Chrysler.
TIER 2 (& LOWER) SUPPLIER: a Supplier who is responsible for providing components,
services, or raw material to another Supplier in the Supply Chain. A Tier 2 supplies a Tier
1, a Tier 3 supplies a Tier 2, and so on. All references to sub-tier or sub-tier supplier
in this manual refer to a Tier 2 (or lower) Supplier, unless otherwise specified.
VERIFICATION SAMPLES: samples created with known defects in order to verify the
performance of Error and Mistake proofing. Verification samples must be clearly marked
and/or identified to prevent shipment to the customer and properly controlled to prevent
degradation and ensure relevance.
WORK IN PROCESS (WIP): product that has not gone through the entire production
process or is incomplete in some way.
111
112
INDEX
Page(s)
Advance Quality Planning (AQP) ............................................... .. 1-9,12-14
AQP Flowchart.................................................................................... .. 7-8
AQP Responsibilities Chart........................................................................ 9
AQP Team Members.................................................................................. 1
A Approval .................................................................................................1,3,4,6,9,45,47,98
Bar Code Labeling.................................................................................. ..42
BSR/NVH .....................................................................17,19,46,94,102,106
Chrysler Development System (CDS) .................................. ..1,2,12,102,109
Comments Sheet .......................................................................................... 6,39,93,94,96,97
Control Plan ....................................................2,12,15,21-22,23,24,34,37,43,46,73,91,92,102
Daily Tooling Capacity .......................................................... ..6,39,40,62,68
Design FMEA ..........................................................................................17, 31,73,91,103,104
Documentation Checklist .....................................................................54-56
DVP&R .......................................................................................... 15,18,21,31,46,91,102,104
Electro-Static Discharge (ESD) Guidelines .................................................26
Element Requirements.....................................................................................................11-47
Error and Mistake Proofing ..................................................... 29,33-35,36,92,93,104,106,111
Error and Mistake Proofing Requirements for Electrical Components ............................... 34-35
Error and Mistake Proofing Requirements for Modules/Sequenced Part Delivery................... 35
First Production Shipment Certification (FPSC) .............................. 3,9,31-32,92,97,98,99,104
First Time Capability (FTC) ................................ 4,5,6,22,36,37,39,40,75-79,94,97,99,105,110
First Time Capability (FTC) Calculation Examples....................................75-79
Forever Requirements ............................................................. 3,9,12,13,18,26,29,32,36,83-88
Frequently Asked Questions ................................................................95-99
Gage and Test Equipment Evaluation..................................................... ..43
Gage R&R................................................................................... ..43,93,105
Glossary ...............................................................................................................101-111
IAA .................................................... 3,29,47,97,105
Incoming Material Certification Plan....................................................... ..23
Initial Process Study............................................................................... 31,45,64-65,93,94,99
Internal PSO Requirements ..................................................................89-94
Layered Process Audit .............................................................. ..26,32,36,72
Lot Acceptance Sampling Table ............................................................................................70
Measurement System Report ............................................................................31,37-38,66-67
N Approval ........................................................................................................................6,9
Net Operating Time for Chrysler Parts ....................................... ..39,105,106
Operating Instructions ...................................................................... ..27-29
Outgoing Material Certification Plan ....................................................... ..24
Packaging Approval...................................................................................41
Part Number, Description, & Change Level...................................................................... 15-16
Parts Handling Plan ..................................................................... ..25-26,92
Parts Packaging and Shipping Specifications ..................................... ..41-42
Performance Matrix...................................................................................71
Process Capability Indices (CP, CPK)........................................ .. 21,45,96,103
Process Performance Indices (PP, PPK) .............................................. 6,37,40,45,71,96,107,110
PPAP ...............................................1,2,3,4,5,6,9,12,13,23,40,45,84,86,88,92,97,105,108,109
Pre-PSO Meeting..................................................................4,5,9,32,37,39,43,45,54,97,99,107
Preventive Maintenance ................................... 6,25,26,27,33,44,73,106,107
Problem Solving ..............................................................................13,91,92
Process Flow Diagram and Manufacturing Flow Chart..20,91,94,105-106,108
Process FMEA ........................................................................ 15,19,21,24,31,36,73-74,91,108
Production Demonstration Run (PDR) .. 5,6,20,21,27,38,39-40,45,46,76,77-79,82,94,97,98,108
Production Validation (PV) Testing ...................4,5,6,9,18,37,46-47,91,94,97,104,108,109,110
PSO Checklist...........................................................................................57
113
PSO Extended Run .......................................................................................................5,81-82

PSO On-Site Visit ......................................4,5,6,9,14,20,28,30,32,36,37,39,40,98,107,108,110
PSO Team Members................................................................................................................4
Reference Manuals ...................................................... .100
Rework and Repair Instructions and Procedures................................ ..28-29
Safety Characteristics ...................................... ..15,28,31-32,35,70,109,110
Special Characteristics ....................... ..17,19,20,21,22,27,31-32,33,36,37,38,43,45,109-110
Supplier Readiness Evaluation (SRE) .... ..4,5,6,9,37,40,46,97,98,99,108,110
Supply Base Management ................................................................. ..12-13
Test Sample Sizes & Frequencies............................................................ ..18
Tooling, Equipment, & Gages Identified .................................................. ..30
Z Approval ..................................3,6,9,25,39,45,97,98
Page numbers in bold indicate the PSO Element Requirement section
Page numbers in italics indicate the glossary entry
114
AQP & PSO MANUAL CHANGE LOG

REVISION
& DATE
5.5
12/2006
5.6
3/2008
SECTION
Entire Document
DESCRIPTION OF CHANGE
Initial Revision
Foreword
Updated foreword.
Acknowledgements
Updated team members.
Scope and Definition
Removed note allowing buyer to provide tool capacity in writing rather than
P.O. from What is a PSO? section.
Added note regarding lack of approval for Chrysler-designed packaging
under 3. Production Validation Testing.
Revised information regarding IAAs under When is PSO Performed? and
Interim Approval Authorization sections.
Added Note 3 (moved from 7.7 of Element Requirements).
PSO Strategy &

Flowchart
Added May be after SRE w/approval to Supplier Conducts PV Testing

box.
Revised and added note to flowchart process step 10 regarding PV testing.
PSO Element
Requirements
Corrected mistakes and omissions in documentation column.

Removed references to the PFMEA Audit Form in Element 4 and Document
Checklist.
Added requirement for tracking progress to 6.5.1.
Added additional requirements for communication of lessons learned
(7.3.2).
Moved Note under 7.7 to PSO Definition section (Note 3).
Removed 8.11 (Part Inspection Standard requirements and renumbered
8.12, 8.13, & 8.14.
Deleted 9.4.2.1 (FIFO dependant traceability).
Added additional traceability requirements (9.6.1 & 9.6.2).
Added requirements for containment of non-conforming material (9.7.2 &
9.7.3).
Added requirement for key personnel hiring (10.2.4).
Added requirements for work station organization and cleanliness (10.4,
10.4.1, & 10.4.2).
Added requirements for temporary rework/repair (10.5.5).
Added requirements for review of station cycle times and FTC as a part of
the SRE (10.4 & note) and renumbered 10.4 through 10.4.5.
Revised FPSC requirements based on new PSO/PPAP gate requirements
(12.5).
Added 15.5 and note under 16.5 regarding PV testing on SRE parts.
Appendix A Forms &

Documents
Updated Document Checklist.

Revised Supplier Readiness Evaluation form to include station cycle times
and FTC results.
Appendix E Forever
Requirements
Updated Forever Requirements appendix to match current electronic-based

system.
Frequently Asked
Questions
Updated and Corrected FAQs.
Glossary
Corrected terminology.
Added definitions for Key Personnel and Station Cycle Time.
Entire Document
Changed DaimlerChrysler, DCC, and DCX to Chrysler.

Revised wording to improve readability.
115
6.0
01/2009
Foreword
Updated foreword.
Acknowledgements
Updated team members.
Scope and Definition
Replaced Scope and Definition section with process-based format for both
AQP and PSO.
Added and updated AQP process from Book of Knowledge
Updated PSO process
Revised PV Testing section to accommodate Component-level PV testing at
Gate C S1 Start
PSO Strategy
PSO Strategy chart removed
PSO Flowchart and

Responsibility chart
PSO Flowchart and Responsibility charts updated
PSO Element
Requirements
Updated documentation column for all elements

Added Element X in front of all element titles
Renamed Quality Planning to Advance Quality Planning and moved to
Element 1; all other elements renumbered accordingly
Added and revised requirements in AQP element to match new forms and
process detailed in the manual
Added detail to 1.2 that Supplier is responsible for sub-tier Supplier quality
Added detail to 1.2.3 regarding sub-tier acceptability criteria
Added 1.2.4 to require cascading of Forever Requirements
Added NOTE under 1.2 regarding exemption from Supply Base
Management requirements
Clauses 1.8 through 1.8.2 incorporated into new 1.1 through 1.1.2.2
Replaced Rolling Top 20 rule in 2.2.2 and 4.2.2 with revised requirement
Revised Occurrence values in the Notes for FMEA elements to
accommodate the new AIAG FMEA values
Added 4.2.1 to require PV testing to be preceded by successful DV testing
Added 7.2.1 and 20.2 for long-term capability requirements
Added 7.3.3 to require verification of last piece against First Piece sample
Removed Qualification from the title of Element 8
Added 8.3.1 requiring inspection frequencies to be based on risk level
Added 8.6.1 requiring sub-components to meet appearance requirements of
the finished product
Modified 8.10 to include PFMEA values when determining inspection
frequencies
Added 18.14 and 18.14.1 for IMDS requirements
Incorporated 10.3.1 into new requirements for Boundary Samples
Added 10.4 through 10.4.4 for Boundary Sample requirements
Changed NOTE under 11.2.2 to requirement 11.2.3
Former requirement 12.3 moved to NOTE under new 12.3.1
FPSC section updated and revised to requirements 12.4 through 12.4.5
NOTE under 13.1.2 incorporated into 13.1.2
Added 14.7 and NOTE for LPA and new Suppliers
Changed name of Element 15 to Supplier Readiness Evaluation and
NOTE under 15.1 changed to requirement 15.1.1
Removed 15.5
Added FTC requirements as 15.5-15.5.1
Changed name of Element 16 to Production Demonstration Run
Removed FTC sub-element heading from Element 16
Removed 16.6
Added Note 3 under 16.6 (formerly 16.7) clarifying FTC at both S1 and PDR
Requirement 16.7.2 changed to NOTE
Added preference for variable data R&Rs to 18.4
Added detail for PM plans to 19.1
Added 19.1.1 regarding improvement of PM plans
116
Added 19.1.2 regarding backups for long-lead replacement parts

Revised 20.1 to improved clarity of part selection for Initial Process Study
Removed NOTE under 20.1
Added requirements for runs that PV test samples come from to 21.1
Added NOTE under 21.1.2 to clarify random selection
Changed 21.2 from approved to accepted for Engineer
Added requirement for PV testing by S1 to 21.4
Added Note under 21.4
Incorporated 21.5.2 into 21.5.1
Added 21.6 and two notes regarding Appearance Approval Report
Appendix A
Added Executive Summary, AQP Open Issues, and AQP Timing Chart
Revised PSO Document Checklist and PSO Checklist
Changed SRE form to Supplier Readiness Evaluation/Trial Run Results
Appendix B
Renamed, revised and expanded the FMEA Guidelines section to

accommodate the new FMEA manual
Appendix E
Revised and updated Forever Requirements section
FAQ
Revised and updated FAQ as necessary

Removed question 5
Glossary
Revised and updated Glossary

Removed AQP definition
Removed Extended Enterprise definition
Added Process Characteristic and Product Characteristic definitions
Entire document
Removed all references to Powerway.com

Changed ASQP Specialist to Supplier Quality Engineer (SQE)
Revised and updated wording to improve clarity and readability throughout
the manual
117
84-231-1227 (REV. 01/2009) Chrysler LLC
PRINTED IN U.S.A.

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Advance Quality Planning &

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Advance Quality Planning &

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ADVANCE QUALITY PLANNING &

Manager Supplier Quality Processes & Training

Supplier Quality Processes & Training

Supplier Quality Processes & Training

Supplier Quality Processes & Training

Sr. Manager CoC International Supplier Quality

Manager International Quality

Manager Supplier Quality (NEA)

Supplier Quality - Exterior

Supplier Quality - Electrical

Supplier Quality Body-In-White

Supplier Quality Chassis

Supplier Quality Chassis

Supplier Quality - Interior

Supplier Quality Powertrain

Powertrain Manufacturing Quality

Requests for revisions or changes to the manual

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ADVANCE QUALITY PLANNING &

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Advance Quality Planning (AQP)

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Process Sign-Off (PSO)

Supplier Readiness Evaluation (SRE)

Production Validation (PV) Testing

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Advance Quality Planning Flowchart

3) Review IRE "Risk

New/Modified part Risk Level

4a) Supplier leads the

4b) Supplier leads the

5b) AQP begins. Conduct

5a) Quality planning phase

COPYRIGHT 2009 CHRYSLER LLC

10) Schedule and

11) Conduct PSO OnSite Visit (including

PSO On-Site Visit Result

12a) Resolve PSO

12b) Submit full PSW/

14) Changes to the

13) Complete PSO

End AQP Process

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Low & Medium

11 PSO On-Site Visit

PSO Visit Result

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ADVANCE QUALITY PLANNING

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PSO ELEMENT REQUIREMENTS

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ELEMENT 1 - ADVANCE QUALITY PLANNING (AQP)