DAIMLERCHRYSLER PROCESS SIGN-OFF SUMMARY REPORT

ALL PROCESS SIGN-OFF ELEMENTS APPROVED: PSO EXTENDED RUN:

SUPPLIER Metrican Tool YES NO YES NO OPTION
MFG. LOCATION Burlington ON SUPPLIER CODE
PART NUMBER(S) PART NAME(S)
CHANGE LEVEL(S) PRE-PSO MEETING DATE
PROGRAM __ PSO ON-SITE VISIT DATE / NUMBER
* Documents with asterisk should be reviewed during AQP meetings and again during the Pre-PSO Documentation Review
PSO PROCESS ELEMENTS
DOCUMENTATION PROCESS
1 PART NUMBER, DESCRIPTION AND Accept Reject Accept Reject
CHANGE LEVEL
*Cross reference sheet Yes No Acceptable Supplier change Yes No
(IF APPLICABLE) notice procedure
1.4 Engineering Standards Identified Evidence of customer change
Yes No notice procedure
*CATIA comments page Process for obtaining the Yes No
with list of applicable standards latest standard revision
(e.g DCC, ENVIRONMENTAL,etc) Accept Reject Accept Reject
2 DESIGN FMEA
*Design FMEA complete Yes No DFMEA updated to include Yes No
& acceptable applicable DV failures
Accept Reject
3 TEST SAMPLE SIZES AND FREQUENCIES
Yes No
*Signed DV and PV plans
*Signed DVP&R (DV complete)
*Signed waivers
Accept Reject Accept Reject
4 PROCESS FMEA Process correlates with
*Process FMEA complete Yes No occurrence and detection Yes No
& acceptable numbers on PFMEA
(IF APPLICABLE) Accept Reject Accept Reject
5 PROCESS FLOW DIAGRAM
& MFG FLOOR PLAN Yes No SPC operations identified Yes No
*Flow diagram on flow diagram
*Manufacturing floor plan Unique equipment numbers
*Work station layout identified on mfg floor plan,
Accept Reject flow diagram, or workstation layout Accept Reject
6 CONTROL PLAN
*Process characteristics Yes No Proper adherance to Yes No
identified on the Control Plan Control Plan
*Verification of mistake Rework/Repair stations
proofing on the Control Plan Accept Reject have acceptable controls
7 QUALITY PLANNING (IF APPLICABLE)
Yes No
*Completed PAP/APQP
PSO Summary Matrix
7.2 Supply Base Management Yes No
* Easy Map, Etc.
Risked sub-components
Level 3 PPAP data
7.3 Problem Solving Methods Yes No
*Example of DOE's, etc.
SID'S for DCC systems
*Example of problem
solving techniques Accept Reject Accept Reject
8 INCOMING MATERIAL QUALIF/ CERT PLAN
Yes No Evidence of Yes No
Certificates of analysis sub-tier monitoring
Copies of sub-tier PSW's Proof of lot contol
*Plan for lot control Proof of traceability
*Plan for traceability

Pg 1 of 5
 PSO PROCESS ELEMENTS
SUPPLIER NAME:
PART NUMBER: DOCUMENTATION PROCESS
Accept Reject Accept Reject
9 PARTS HANDLING PLAN
Yes No Evidence of acceptable Yes No
*Routing/Traveler Cards parts handling
*Parts Handling Plan Yes No
*Container Maintenance Acceptable method of
plan Accept Reject inventory control Accept Reject
10 OPERATING INSTRUCTIONS
Yes No Visual displays clearly present Yes No
*Work instructions (WI's) at each station
*Inspection instructions Operators follow WI's
*Rework/repair Evidence of proper operator
instructions (IF APPLICABLE) Accept Reject training Accept Reject
11 TOOLING, EQUIPMENT AND GAGES
IDENTIFIED Yes No STR in agreement with Supplier's Yes No
*Tooling and equipment list manufacturing facility
*Supplier tool record DCC ownership tags present
12 SPECIAL PRODUCT & PROCESS Accept Reject Accept Reject
CHARACTERISTICS IDENTIFIED
Yes No SPC performed for identified Yes No
*FPSC plan acceptable and special characteristics
contains special process/
product characteristics Accept Reject Accept Reject
13 PROCESS MONITORING
Yes No Acceptable 1st piece approval Yes No
*Control charts process
*1st piece approval procedure 1st piece approval records
Control & Performance charts
14 ERROR AND MISTAKE PROOFING Accept Reject maintained appropriately Accept Reject

Yes No Boundary samples created Yes No

*Error & mistake proofing plan & utilized
*List of error & mistake proofing Mistake proofing contingency
Accept Reject plan with audible/visual alarm Accept Reject
15 LAYERED PROCESS AUDIT PLAN
Yes No Yes No
*Acceptable LPA plan Acceptable LPA performed
*Frequency & structure chart
16 EVIDENCE OF Accept Reject Accept Reject
PRODUCT SPECIFICATIONS
Yes No Completed & approved Yes No
*SRE completed and Measurement System
acceptable Accept Reject Verification Report Accept Reject
17 LINE SPEED DEMONSTRATION
Yes No
Contingency plan for
bottlenecks (IF APPLICABLE)
Line Speed Observed FTC:
Accept Reject Accept Reject
18 OUTGOING QUALIFICATION PLAN
Yes No Evidence of non-conformance Yes No
*Outgoing inspection plan containment
*Part Inspection Standard Evidence of outgoing audits
Accept Reject (USING PART INSPECTION STANDARD) Accept Reject
19 PARTS PACKAGING & SHIPPING SPECS
*Dunnage design sign-off Yes No Yes No
from MHE (IF APPLICALBLE) *Acceptable container
* Packaging & shipping plan management plan
20 GAGE AND TEST EQUIPMENT EVALUATION Accept Reject Accept Reject

Yes No Appropriate gages used in Yes No

*Gage R&R studies the process
*Calibration plan & schedule Calibration performed
according to schedule

Pg 2 of 5
 PSO PROCESS ELEMENTS
SUPPLIER NAME:
PART NUMBER:
DOCUMENTATION PROCESS
Accept Reject Accept Reject
21 PREVENTIVE MAINTENANCE PLANS
Yes No PM performed according to Yes No
*PM plan schedule
*PM schedule Robust PM process
*PM procedures & WI's All tooling/equipment listed on
Accept Reject PM schedule Accept Reject
22 INITIAL PROCESS STUDY
Yes No Yes No
Deviations (IF APPLICABLE) Acceptable FTC
Acceptable process capability
Sample size: Ppk requirement:

PSO PROCESS ELEMENTS REQUIRED FOR FULL APPROVAL

DOCUMENTATION PROCESS
Accept Reject Accept Reject
23 PACKAGING SHIPPING TEST APPROVAL
Yes No Yes No
Signed shipping/simulation Shipping/simulation testing
test approval (MHE ULD SHEET) Accept Reject complete Accept Reject
24 PRODUCTION VALIDATION
TESTING COMPLETE Yes No Yes No
Signed DVP&R (PV complete) BSR/NVH testing complete
Signed Waivers (IF APPLICABLE) PV testing complete
Repair/rework process
Accept Reject validation complete (IF APPLICABLE) Accept Reject
25 CONTINUOUS CONFORMANCE (CC)
Continuous Conformance team Yes No CC team is sufficient to Yes No
identified & trained support post-PSO activities
Warranty process flow diagram Acceptable process for
Forever requirements warranty analysis Yes No
submission procedure Family PV testing agreed to
by the PSO team
Vehicle families included in family PV:

CORRECTIVE ACTION REQUIRED Yes No Date

ON-SITE REVISIT REQUIRED Yes No Date

Process Sign-Off Team Manufacturing Facility

ENGINEERING PRINT NAME, SIGN AND DATE QUALITY ASSURANCE MANAGER PRINT NAME, SIGN AND DATE

SUPPLIER QUALITY PRINT NAME, SIGN AND DATE MANUFACTURING MANAGER PRINT NAME, SIGN AND DATE

PRINT NAME, SIGN AND DATE PLANT MANAGER PRINT NAME, SIGN AND DATE

Addditional Signatures Needed for Internal PSO's

PRODUCT ENGINEERING PRINT NAME, SIGN AND DATE MANUFACTURING LINE SUPERVISOR PRINT NAME, SIGN AND DATE

RESIDENT ENGINEERING MANAGER PRINT NAME, SIGN AND DATE MQAS COORDINATOR PRINT NAME, SIGN AND DATE

AME TOOL ENGINEER PRINT NAME, SIGN AND DATE

AME SENIOR MANAGER PRINT NAME, SIGN AND DATE

1st or 2nd Party PSO Lead PRINT NAME, SIGN AND DATE

Pg 3 of 5
SUPPLIER Metrican Tool PROGRAM
MFG. LOCATION Burlington On SUPPLIER CODE DaimlerChrysler
PART NUMBER(S) PART NAME(S) PSO
CHANGE LEVEL(S) PRE-PSO MEETING DATE 5th Edition
PSO ON-SITE VISIT DATE / NUMBER

MEASUREMENT SYSTEM VERIFICATION REPORT

As part of the PSO, the actual measurement process must be witnessed by the PSO Team.
- A minimum of 3 characteristics are to be checked. For any given part, assembly, or process,
the number of characteristics selected depends upon the complexity.
- A minimum of 30 randomly selected samples shall be checked during the PSO on-site visit.
- Variable data is preferred but attribute data is acceptable.
- Refer to the Ppk Capability Matrix (Appendix B of the PSO 5th Edition Manual) for Ppk requirements.
- For attribute data, a 30 piece sample with one or more non-conformances is unacceptable.
- All deviations shall be listed in the COMMENTS section of this document.

SUMMARY EXAMPLE
QUANTITY QUANTITY FTC PERCENTAGE
CHARACTERISTIC SPECIFICATION METHOD OF MEASUREMENT PP / PPK PROCESS ACC/REJ
ATTEMPTED ACCEPTED (without repair)

Length (3.6 - 7.5 mm) CALIPER 30 30 100% 1.6/1.7 REJ

Hole Size (2.0 ± 0.02 mm) CMM MACHINE 30 28 93% 2.2/2.3 ACC

Number of parts witnessed: Witnessed By:

DATA
QUANTITY QUANTITY FTC PERCENTAGE
CHARACTERISTIC SPECIFICATION METHOD OF MEASUREMENT PP / PPK PROCESS ACC/REJ
ATTEMPTED ACCEPTED (without repair)

COMMENTS:

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SUPPLIER Metricna Tool PROGRAM
MFG. LOCATION Burlington ON SUPPLIER CODE
DaimlerChrysler
PART NUMBER(S) PART NAME(S)
PSO
CHANGE LEVEL(S) PRE-PSO MEETING DATE
5th Edition
PSO ON-SITE VISIT DATE / NUMBER

PROCESS SIGN-OFF
COMMENTS SHEET
ELEMENT NO. ISSUE/ACTION RESPONSIBILITY TARGET DATE
SUPPLIER Metricna Tool PROGRAM
MFG. LOCATION Burlington ON SUPPLIER CODE
DaimlerChrysler
PART NUMBER(S) PART NAME(S)
PSO
CHANGE LEVEL(S) PRE-PSO MEETING DATE
5th Edition
PSO ON-SITE VISIT DATE / NUMBER

PROCESS SIGN-OFF
COMMENTS SHEET
ELEMENT NO. ISSUE/ACTION RESPONSIBILITY TARGET DATE
SUPPLIER Metricna Tool PROGRAM
MFG. LOCATION Burlington ON SUPPLIER CODE
DaimlerChrysler
PART NUMBER(S) PART NAME(S)
PSO
CHANGE LEVEL(S) PRE-PSO MEETING DATE
5th Edition
PSO ON-SITE VISIT DATE / NUMBER

PROCESS SIGN-OFF
COMMENTS SHEET
ELEMENT NO. ISSUE/ACTION RESPONSIBILITY TARGET DATE
SUPPLIER Metricna Tool PROGRAM
MFG. LOCATION Burlington ON SUPPLIER CODE
DaimlerChrysler
PART NUMBER(S) PART NAME(S)
PSO
CHANGE LEVEL(S) PRE-PSO MEETING DATE
5th Edition
PSO ON-SITE VISIT DATE / NUMBER

PROCESS SIGN-OFF
COMMENTS SHEET
ELEMENT NO. ISSUE/ACTION RESPONSIBILITY TARGET DATE
SUPPLIER Metrican Tool PROGRAM
MFG. LOCATION Burlington ON SUPPLIER CODE
PART NUMBER(S) PART NAME(S)
CHANGE LEVEL(S) PRE-PSO MEETING DATE
PSO ON-SITE VISIT DATE / NUMBER

Line Speed Demonstration

Net DC
Quoted Tooling Line Speed Part Quantity Duration of Line Speed % of DC
Operating Part Quantity Ran FTC
Capacity Required Accepted Run Demonstrated Capacity
Time

COMMENTS

Note: Pieces per hour shall be greater than or equal to the Line Speed Required.
FTC shall be 90% or greater or a signed waiver from the appropriate Supplier Quality Manager is required.

Summary Example
Item Process Feature / Part Process Meas. Part/Proc Quantity Quantity
USL UCL LCL LSL Pp Ppk
# Characteristic /Part1 Freq. Avg. Attempted Accepted
1 P025 Gap - Machine 66 Part 2/Shift 0.097 0.009 0.0874 0.0851 0.077 2.5 2.28 30 30
2 P025 Gap - Machine 67 Part 2/Shift 0.097 0.009 0.0874 0.0851 0.077 2.54 2.41 30 30

Initial Process Study

Item Process Feature / Part Process Meas. Part/Proc Quantity Quantity
USL UCL LCL LSL Pp Ppk
# Characteristic /Part1 Freq. Avg. Attempted Accepted
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Notes: 1 Measurement Taken During In-Process / or Final Inspection