TEAM FEASIBILITY COMMITMENT

Customer: Date:

Part Number: Part Name:

Revision Level

Feasibility Considerations
Our product quality planning team has considered the following questions
The drawings and/or specifications provided have been used as a basis for
analyzing the ability to meet all specified requirements. All "no" answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the specified requirements.

YES NO CONSIDERATION
Is product adequately defined (application requirements, etc. to enable
feasibility evaluation?
Can Engineering Performance Specifications be met as written?
Can product be manufactured to tolerances specified on drawing?
Can product be manufactured with process capability that meet requirements?
Is there adequate capacity to produce product?
Does the design allow the use of efficient material handling techniques?
Can the product be manufactured within normal cost parameters? Abnormal cost
considerations may include:
- Costs for capital equipment?
- Costs for tooling?
- Alternative manufacturing methods?
Is statistical process control required on the product?
Is statistical process control presently used on similar products?
Where statistical process control is used on similar products:
- Are the processes in control and stable?
- Does process capability meet customer requirements?

Conclusion

Feasible Product can be produced as specified with no revisions.

Feasible Changes recommended (see attached).
Not Feasible Design revision required to produce product within the specified requirements.

Sign-Off

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

 PRODUCT QUALITY PLANNING SUMMARY AND SIGN-OFF
DATE:

PRODUCT NAME: PART NUMBER/ Rev:

CUSTOMER: MANUFACTURING PLANT:

1. PRELIMINARY PROCESS CAPABILITY STUDY QUANTITY

REQUIRED ACCEPTABLE PENDING*
Ppk - SPECIAL CHARACTERISTICS

2. CONTROL PLAN APPROVAL (If Required) APPROVED: YES / NO* DATE APPROVED

3. INITIAL PRODUCTION SAMPLES

CHARACTERISTIC CATEGORY QUANTITY
CHARACTERISTICS
SAMPLES PER SAMPLE ACCEPTABLE PENDING*
DIMENSIONAL
VISUAL
LABORATORY
PERFORMANCE

4. GAGE AND TEST EQUIPMENT

MEASUREMENT SYSTEM ANALYSIS QUANTITY
REQUIRED ACCEPTABLE PENDING*
SPECIAL CHARACTERISTIC

5. PROCESS MONITORING
QUANTITY
PROCESS MONITORING INSTRUCTIONS REQUIRED ACCEPTABLE PENDING*
PROCESS SHEETS
VISUAL AIDS

6. PACKAGING/SHIPPING QUANTITY
REQUIRED ACCEPTABLE PENDING*
PACKAGING APPROVAL
SHIPPING TRIALS

7. SIGN-OFF

TEAM MEMBER/TITLE/DATE TEAM MEMBER/TITLE/DATE

TEAM MEMBER/TITLE/DATE TEAM MEMBER/TITLE/DATE

TEAM MEMBER/TITLE/DATE TEAM MEMBER/TITLE/DATE

* REQUIRES PREPARATION OF AN ACTION PLAN TO TRACK PROGRESS.

 A-1 DESIGN FMEA CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Was the DFMEA prepared using the DaimlerChrysler, Ford,
and General Motors Potential Failure Mode and Effects
1 Analysis (FMEA) reference manual, and applicable
customer specific requirements?

2 Have historical campaign and warranty data been reviewed?

Have Best practices and lessons learned from similar parts
3
DFMEA been considered?
4 Does the DFMEA identify Special Characteristics?

Have Pass-trought characteristics (glossary) been identified

5 and reviewed with affected suppliers for FMEA aligment and
appropriate controls in the supply base?
Have special characteristics designated by the customer or
6 organization been reviewed with affected suppliers to assure
FMEA aligment?
Have design characteristics that affect high risk priority
7
failure modes been identified?
Have appropriate corrective actions been assigned to high
8
risk priority numbers?
Have appropriate corrective actions been assigned to high
9
severity numbers?
Have risk priorities been revised when corrective actions
10
have been completed and verified?

Revision Date:

Prepared By:

Page 3 of 15
 A-2 DESIGN INFORMATION CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
A. General
1 Does the design require:
a l New materials? /
b l Special tooling? /
c l New Technology or Process? /
2 Has assembly build variation analysis been considered?
3 Has Design of Experiments been considered?
4 Is there a plan for prototypes in place? /
5 Has a DFMEA been completed? /
6 Has a DFMA (Design for Manufacturability and Assembly) been completed?
7 Have service and maintenance issues been considered?
8 Has the Design Verification Plan been considered?
9 If yes, was it completed by a cross functional team?
Are all specified tests, methods, equipment and acceptance criteria clearly defined and
10
understood?
11 Have Special Characteristics been selected? /
12 Is bill of material complete? /
13 Are Special Characteristics properly documented?
B. Engineering Drawings
14 Are reference dimensions identified to minimize inspection layout time?
15 Are sufficient control points and datum surfaces identified to design functional gages?
16 Are tolerances compatible with accepted manufacturing standards?
17 Can existing and available inspection technology measure all design requirements?
Is the customer designated engineering change management process used to manage
18
engineering changes?

Page 4 of 15
 A-2 DESIGN INFORMATION CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
C. Engineering Performance Specifications
19 Have all special characteristics been identified? /
Are test parameters sufficient to address required use conditions i.e. production,
20
validation and end use?
Have parts manufactured at minimum and maximum specifications been tested, as
21
required?
22 Will all product testing be done in-house? /

23 If not, is it done by an approved suplier? /

Is the specified in-process performance test sampling size and /or frequency consistent
24
with manufacturing volumes?
25 Has customer approval been obtained e.g. for testing and documentation?
D. Material Specification
26 Are special material characteristics identified? /
Where the organization is design responsible, are specified materials, heat treat and
27 surface treatments compactible with the durability requirements in the identified
environment?
28 Where required, are the intended material suppliers on the customer approved list?
Has the organization developed and implemented a process to control incoming material
29
quality?
Have material characteristics requiring inspection been identified? If
30
so,
a l Will characteristics be checked in-house? /

b l If check in house, is test equipment available? /

c l If check in house, are competent people available to assure accurate testing?

31 Will outside laboratories be used? /

l Does the organization have a process in place to assure laboratory competency such
a as an acreditation? NOTE: Competency needs to be assured, regardless of the
organization's relationship with the laboratory
32 Have the following material requirements been considered:
l Handling, including environmental aspects? /
a
l Storage, including environmental aspects? /
b
l Have the materials/substance composition been reported in accordance with
c
customer requirements e.g. IMDS? /
l Have polymeric parts been identified/marked per customer requirements?
d
/

Page 5 of 15
 A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
1 Does the design require:
l New materials?
a
/
l Quick change?
b
/
l Volume fluctuations?
c
/
l Mistake proofing?
d
/
Have lists been prepared identifying: (Include all
2
suppliers)
l New equipment?
a
/
l New tooling?
b
/
l New test equipment (including checking
c
aids)? /
Have acceptance criteria been agreed upon for:
3
(include all suppliers)
l New equipment?
a
/
l New tooling?
b
/
l New test equipment (including checking
c
aids)? /
Will a preliminary capability study be conducted at
4
the tooling and/or equipment manufacturer?
Has test equipment feasibility and accuracy been
5
established?
Is a preventive maintenance plan complete for
6
equipment and tooling?
Are setup instructions for new equipment and
7
tooling complete and understandable?
Will capable gages be available to run preliminary
8 process capability studies at the equipment
supplier's facility?
Will preliminary process capability studies be run
9
at the processing plant? Page 6 of 15
 A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Have process characteristics that affect special
10
product characteristics been identified?
Were special product characteristics used in
11
determining acceptance criteria?
Does the manufacturing equipment have
12 sufficient capacity to handle forecasted production
and service volumes?
Is testing capacity sufficient to provide adequate
13
testing?
Has the measurement equipment been verified
14 and documented showing qualification for the
required scope of measurement and testing?

Revision Date

Page 7 of 15
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Is the customer assistance or approval required for the
1
development of the control plan?
Has the supplier identified who will be the quality liaison
2
with the customer?
Has the supplier identified who will be the quality liaison
3
with its suppliers?
Has the quality management system been reviewed and
4
approved per customer specific requirements?
5 Are there sufficient personnel identified to cover:
a l Control plan requirements?

b l Layout inspection?
c l Engineering performance testing?
d l Problem reaction and resolution analysis?
6 Is there a documented training program that:
a l Includes all employees? /
b l Lists whose been trained? /
c l Provides a training schedule? /
7 Has training been completed for:
a l Statistical process control? /
b l Capability studies? /
c l Problem solving? /
d l Mistake proofing? /
e l Reaction plans? /
f l Other topics as identified? /
Is each operation provided with process instructions that
8
are keyed to the control plan?
Are standard operator instructions accesible at each work
9
station?

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE DAIMLERCHRYSLER, FORD MOTOR CO., AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 8 of 15
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Do operations instructions include pictures and diagrams?
10
Were operator/team leaders involved in developing
11
standard operator instructions?
12 Do inspection instructions include:
l Easily understood engineering performance
a
specifications?
l Test frequencies? /
b
c l Sample sizes? /
d l Reaction plans? /
l Documentation requirements?
e
/
13 Are visual aids:
l Appropriate, Easily understood and legible?
a
/
b l Available? /
c l Accessible? /
l Approved? /
d
l Dated and current? /
e
Is there a procedure to implement, maintain, and
14 establish reaction plans, for issues such as out of control
conditions based on statistical process control?
Is there an identified problem resolution process that
15
include root cause analysis?

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE DAIMLERCHRYSLER, FORD MOTOR CO., AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 9 of 15
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Are the latest drawings and specifications available for the
16
operator, in particular at the point of the inspection?
l Have engineering tests (dimensional, material,
appearance, and performance) been completed and
documented as required in accordance with customer
requirements? /
Are the current forms/logs available for appropriate
17
personnel to record inspection results?
Are the following available and placed at the appropriate
18
points of operation:
l Monitoring and measurement devices?
a
/
b l Gage instructions? /
c l Reference samples? /
d l Inspection logs? /
Have provisions been made to certify and calibrate gages
19 and test equipment at a defined frecuency that is
appropriate?
Have required measurement system capability studies
20
been:
l Completed? /
a
b l Acceptable? /
Have initial process capability studies been conducted per
21
customer requirements?
Are layout inspection equipment and facilities adequate to
provide initial and ongoing layout of all details and
22
components in accordance with customer requirements?

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE DAIMLERCHRYSLER, FORD MOTOR CO., AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 10 of 15
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Is there a procedure for controlling incoming material that
23
may include, for example, the following items:
l Characteristics to be inspected? /
a
b l Frequency of inspection? /
c l Sample size? /
l Designated location for approved product? /
d
l Disposition of nonconforming products? /
e
Have sample production parts have been provided per
24
customer requirements?
Is there a procedure to identify, segregate, and control
25
nonconforming products to prevent shipment?
Are rework/repair procedures available to assure
26
conformity product?
Is there a procedure to requalify repaired/reworked
27
material?
Has a master sample, if required, been retained as part of
28
the Part Approval Process?
29 Is there an appropriate lot traceability procedure?
Are periodic audits of outgoing products planned and
30
implemented?
Are periodic assessments of the quality system planned
31
and implemented?
Has the customer approved the packaging and the
32
packaging specification?

Revision Date

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE DAIMLERCHRYSLER, FORD MOTOR CO., AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 11 of 15
 A-5 FLOOR PLAN CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
1 Have lean concepts been applied in considering material flow?
Does the floor plan identify all required process and inspection
2
points?
Have clearly marked areas for all material, tools, and equipment
3 at each operation been considered?

Has sufficient space been allocated for all equipment?

4

5 Are process and inspection areas:

l Of adequate size? /
a
l Properly lighted? /
b
Do inspection areas contain necessary equipment and record
6
storage?
7 Are there adequate:
l Staging areas? /
a
l Impound areas? /
b
Are inspection points logically located to prevent shipment of
8
nonconforming products?
Are there controls for each process to eliminate contamination or
9
inapropriate mixing of product?
Is material protected from overhead or air handling systems
10
contamination?
Have facilities been provided for final product audit?
11
Are the facilities adequate to control movement of
12
nonconforming incoming material?

Revision Date
Prepared By:

Page 12 of 15
 A-6 PROCESS FLOW CHART CHECKLIST
Customer or Internal Part Number
Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Does the flow chart illustrate the entire process
1 from receiving through shipping, include outside
processes and services?
In the development of the Process Flow Chart,
2 was the DFMEA used, if available, to identify
specific characteristics that may be critical?
Is the flow chart keyed to product and process
3
checks in the control plan and PFMEA?
Does the flow chart describe how the product will
4 move, i.e., roller conveyor, slide containers, etc.?

Has the pull system/optimization been considered

5
for this process?
Have provisions been made to identify and
6
inspect reworked product before being used?
Are material controls for movement and staging of
product include appropriate identification properly
7 defined and implemented? The controls should
address incoming supplier product as well as
subcontrated processes

Revision Date

Prepared By:

Page 13 of 15
 A-7 PROCESS FMEA CHECKLIST
Customer or Internal Part Number
Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Was the Process FMEA prepared by a crossfunctional
team? Has the team take in account all customer specific
1 requirements, including FMEA methodologies as shown in
the current edition of the FMEA?

Have all operations including subcontrated, or outsourced

2 processes and services been considered?

Have all operations affecting customer requeriments,

including fit, function, durability. Governmental regulations
3
and safety been identified and listed sequencially?

4 Were similar part/process FMEA's considered?

Have historical campaign and warranty data been reviewed
5
and used in the analysis?
Have you applied the appropriate controls to address all the
6
identified failure modes?
Were severity, detection and occurrence revised when
7
corrective action was completed?
Do the effects consider the customer in terms of the
8 subsequent operation, assembly, and product?

Were customer plant problems used as an aid in developing

9
the Process FMEA?
Have the causes been described in terms of something that
10
can be corrected or controlled?
Have provisions been made to control the causes of the
11 failure mode prior to subsequent or the next operation?

Revision Date

Prepared By:

Page 14 of 15
 A-8 CONTROL PLAN CHECKLIST
Customer or Internal Part Number Revision Level

Person Due
Question Yes No N/A Comment / Action Required
Responsible Date
Was the control plan developed according to the
1 methodology described in Chapter 6 of this APQP
manual?
Have all the controls identified in the PFMEA been
2
included in the control plan?
Are all special product/process characteristics included in
3
the control plan?
Were DFMEA, and PFMEA used to prepare the control
4
plan?
Are material specifications requiring inspection identified?
5
Does the control pan address incoming
6 (material/components) through processing/assembly
including packaging?
Are engineering performance testing requirements
7
identified?
Are gages and test equipment available as required by
8
the control plan?
If required, has the customer approved the control plan?
9
Are gage methodology and compactibility appropriate to
10
meet customer requirements?
Have measurement system analysis been completed in
11 accordance with customer requirement?

Are sample sizes based upon industry standards,

statistical sampling plan tables, or other statistical
12
process control methods or techniques?

Revision Date
Prepared By:

Page 15 of 15