Technical Site Assessment Guide
Technical Site Assessment Guide
Instructions: Complete entire form (YELLOW TABS). Use the "Prompts" area for additional
information and as a guide for scoring. During plant tour, look for evidence of
systems in use. Note observations and questions to be discussed
at summary meeting. Use team consensus scoring. To be able to score 2
points the requirements for 1 point must be met. 2 points earned signifies
that the supplier is at (or near) best practices.
Deficient "Critical" questions require an action plan with follow-up. It is the
Purchasing Representative's responsibility to ensure action is taken
in a timely manner.
The proper use of this evaluation process requires appropriate training and certification
of the user by the Solero Technologies Global Supply Management Group or its designate.
Only those Solero Technologies personnel so qualified may use this process.
Print using Macros only. Page #'s are listed for each
question on SCOREWORKSHEET tab.
Go To COVER PAGE tab for Instructions
This letter will confirm the times and dates for a Solero Technologies Supplier Risk and Quality
Assessment to be performed at your facility by the following Solero Technologies personnel -
Names Titles
Please have appropriate personnel available to discuss and substantiate the following topics -
The attached Supplier Questionnaire must be completed and returned to your Solero Technologies Supplier
Development Representative at least one week prior to the evaluation unless otherwise agreed to.
Solero Technologies personnel will be dressed business/casual unless otherwise agreed to.
Sincerely,
Time Day 1
8 AM Arrival
8 - 8:30 Opening conference
- introductions and overview of the assessment plan
8:30 - 9:00 Plant familiarization tour
9:00 - 11:45 Start assessment [tour plant following process flow]
11:45 - 12 Team update meeting
12:00 - 12:30 Working lunch
12:30- 3:30 Continue assessment
Time Day 2
8 AM Review concerns from Day 1
8:30 - 11:30 Continue assessment [as required]
11:30 - 12 Assessment team caucus
12:00 - 12:30 Working lunch
12:30 - 2:00 Assessment team caucus
2:00-3:00 Exit meeting - Report findings / score to supplier
Phone # Certificate #
Expiration
Certification: ISO/TS Registrar:
Provided to BW Other
Describe Parts / Service for Which This Assessment Applies:
EVALUATION SUMMARY
SCORE Critical * Quality Systems
Actual Possible
Business
Safety/Environmental
Training
Incoming Material
Material Control
Production System
Quality
Setup Practices
Facilities
Maintenance
Dimensional Insp. & Test
Measurement System
Shipping
Quality System
Purchasing System
Process Planning
Design
Raw Score
Final Status
BUSINESS B1 2 5 SHIPPING S1 2 16
B2 2 - S2 1 -
B3 2 6 S3 2 -
B4 2 - S4 2 -
B5 2 - S5 2 -
B6 2 -
B7 2 - QUALITY QS1 2 17
SYSTEM QS2 2 -
SAFETY/ S/EI1 2 7 QS3 2 -
ENVIR ISSUES S/EI2 2 - QS4 2 -
QS5 2 -
TRAINING T1 2 - QS6 2 -
T2 2 - QS7 2 18
T3 2 - QS8 2 -
T4 2 - QS9 2 -
QS10 2 -
INCOMING IM1 2 8 QS11 2 -
MATERIAL IM2 2 - QS12 2 19
IM3 2 - QS13 2 -
IM4 1 -
IM5 2 - PURCHASING PS1 2 -
IM6 2 9 SYSTEM PS2 2 -
IM7 2 - PS3 2 -
PS4 1 -
MATERIAL MC1 1 - PS5 1 19/20
CONTROL MC2 2 -
MC3 2 - PROCESS PP1 2 21
MC4 2 - PLANNING PP2 2 -
MC5 1 10 PP3 2 -
MC6 2 - PP4 2 -
MC7 2 - PP5 2 -
MC8 2 - PP6 2 -
MC9 2 - PP7 2 -
MC10 2 - PP8 2 -
MC11 2 11
MC12 2 - DESIGN D1 - - 22
D2 1 -
QUALITY Q1 2 - D3 1 -
Q2 2 - D4 1 -
Q3 2 - D5 1 -
Q4 2 - D6 1 -
Q5 2 12 D7 1 -
Q6 2 - D8 1 23
Q7 2 - D9 1 -
D10 2 -
SETUP SP1 2 - D11 2 -
PRACTICES SP2 2 - D12 1 -
SP3 1 - D13 - - -
D14 2 24
FACILITIES F1 2 13 D15 - - -
F2 2 - D16 1 -
D17 - - -
MAINTENANCE M1 2 - D18 - - -
M2 2 - D19 - - -
DIMENSIONAL DIT1 2 14
INSP & TEST DIT2 1 -
DIT3 1 - Score Applicable % Possible
DIT4 2 -
DIT5 1 - CRITICAL SCORE 28
DIT6 2 -
MEASUREMENT MS1 2 15 Quality System
SYSTEMS MS2 2 -
SCORE
75
MS3 2 -
MS4 2 -
MS5 1 -
MS6 1 -
STATUS
BUSINESS B 14
SAFETY/ S/EI 4
ENVIR ISSUES Question Score Applicable Possible
TRAINING T 8 SHIPPING S 9
INCOMING IM 13 QUALITY QS 26
MATERIAL SYSTEM
MATERIAL MC 22 PURCHASING PS 8
CONTROL SYSTEM
QUALITY Q 14 PROCESS PP 16
PLANNING
SETUP SP 5
PRACTICES DESIGN D 16
FACILITIES PL 4
Status
Acceptable:
100% Criticals and >93% Quality Systems compliance
Conditional:
79-99% Criticals and/or 69%-93% Quality Systems compliance
Unacceptable:
<79% Criticals or <70% Quality Systems compliance
B1 Does the supplier have a formalized quality 0 1 2 Score= 0 if No or verbal commitment, 1 if a plan exists but is not
QS plan that is linked to a strategic business linked or needs improvement, 2 if Yes and formally linked to
plan? strategic business plan with timing and responsibilities identified.
If no formal quality plan exists ask the following questions: B1 shall score= 0 if No solid and well thought out answers are
The score is then applied to B1 > see prompts >> given., 1 if responses are immediate and deliberate, 2 = not
possible. These questions are typically directed at small suppliers.
What is your long term business strategy? Ask to see strategy.
What recent changes or improvements have What were the justifications for improvements?
you made to the facility? What new
equipment have you purchased recently?
What is the dollar investment of these $ What is the Return On Investment (ROI)?
improvements?
B2 Does management have a quality objective? 0 1 2 Score= 0 if No, 1 if Yes and documented,
QS 2 if Yes and evidence of communication to employees and
progress is evident. Ask to see their Mission Statement or
whatever is used to communicate their quality philosophy.
Does it address manufacturing responsibility for quality?
Do employees know what it means?
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B4 Does the supplier have a formalized business 0 1 2 Score= 0 if No, 1 if Yes but lacking in formality and control, 2 if
interruption (contingency) plan? Yes and plan accounts for failures due to environmental,
organized or deliberate work stoppages, utilities, equipment,
and communications failures.
B5 Are quality responsibilities defined throughout 0 1 2 Score= 0 if No, 1 if Yes but lacking in formality and control, 2 if
the organization? Yes and an organization chart exists and shows quality
responsibility.
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B6 Is there an independent and dedicated quality 0 1 2 Score= 0 if No, 1 if Yes but part time or insufficiently staffed,
function? 2 if Yes and function includes engineering personnel
who focus on preventive quality.
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B7 Is the work force stable and morale positive? 0 1 2 Score= 0 if No, 1 if Yes, 2 if yes, morale is excellent and
a business focus on assuring job satisfaction exists.
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Describe the pay system
Incentive pay for part production ? Other?
Employee Turnover? Hourly? Salaried?
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S/EI2 Does the supplier have a formal safety policy? 0 1 2 Score= 0 if No, 1 if Yes and policy is documented, 2 if Yes and
evidence exists that supplier is proactive rather than reactive.
How are safety problems resolved? Look for: use of personal protective equipment, posting of safety
statistics, MSDS (safety data sheets) availability, safety training
and awareness activities.
Ask about current issues.
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Training
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* top
T1 Are training resources available for all 0 1 2 Score= 0 if No, 1 if Yes but process is not formalized or needs
employees? improvement, 2 if Yes and procedures, training matrix,
check sheets are documented w/ evidence that both hourly and
salaried employees are involved. Records show proper training
is received by all employees prior to performing their job function.
Training system is monitored for effectiveness.
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T2 Is Employee Involvement / team / continuous 0 1 2 Score= 0 if No, 1 if Yes but process is not formalized or needs
QS improvement training available for all improvement, 2 if Yes and procedures are documented with
employees? evidence that both hourly and salaried employees are actively
involved on teams. Continuous improvement suggestions are
actively solicited. The system is monitored for effectiveness and
improvements have been documented.
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T3 Does the supplier have a tuition 0 1 2 Score= 0 if No, 1 if Yes for job related, 2 if Yes for all employees
reimbursement program? which includes personal development.
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T4 Are processes performed by qualified 0 1 2 Score= 0 if resources not adequately identified, 1 if resources
personnel? identified and some evidence exists, 2 if operators are certified.
Layout technicians have been adequately trained and are
experienced including GD&T/CMM. Certificates are available.
If NDT is performed, similar experience, certification is evident.
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How are training and performance problems resolved? Progressive discipline, re-training, coaching.
IM2 Are inspection sampling plans consistent 0 1 2 Score= 0 if no controls in place or informal receiving inspection
QS with a zero defect philosophy? plan is utilized, 1 if formal process exists based on MIL-STD 105E
or other documented sampling plan, 2 if receiving inspection plans
are consistently followed and utilize zero defect (C=0) criteria.
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IM3 Does the supplier verify that customer 0 1 2 Score= 0 if No, 1 if Yes, 2 if Yes w/ example
supplied product meets requirements? [n/a if customer does not supply product].
Do records indicate status of customer-supplied product?
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IM4 Are appropriate electronic communication 0 1 Score= 0 if No or limited usage, 1 if Yes and evidence of use.
(EDI / Bar code) tools utilized with suppliers? Review transmissions, schedules, and equipment availability.
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IM5 Is there a supplier quality assurance function? 0 1 2 Score= 0 if No or an informal system exists, 1 if there is active
supplier quality activity, 2 if an SQA process has been implemented
across the supply base and improvements in the quality of
purchased materials are documented.
System exists for measuring supplier quality performance;
Suppliers are periodically informed of their performance
A supplier evaluation process exists and sourcing decisions
reflect evaluation scoring. Supplier performance measures are
tracked and trended.
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Material Control * top
MC1 Are there documented procedures for 0 1 Score= 0 if No or not followed, 1 if Yes per procedure
handling, storage, packaging, preservation, Do these procedures prevent damage and ensure preservation?
and delivery? Does it guarantee effective inventory control? Does it provide
for periodic assessments to detect deterioration?
Verify that procedures are compliant with BW requirements.
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MC2 Is product clearly identified throughout 0 1 2 Score= 0 if No clear identification, 1 if product identified by
the process? part number and routing, 2 if inspection status identified.
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MC3 Is your product traceable after shipment to your 0 1 2 Score= 0 if No traceability, 1 if traceable to production lot/date,
QS customer? 2 if individual product identified by serial number.
'Where applicable' is product traceable to process and employee?
MC4 Is there a system to ensure "First In First Out"? 0 1 2 Score= 0 if No or not followed, 1 if Yes but system is manual
2 if formal system and automated through Fixed Order Point,
MRP, MRPII, ERP, Kanban
First In First Out refers to the suppliers ability to manage their
stock so the material is used in the order it was received.
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MC6 Do you use returnable containers? 0 1 2 Score= 0 if No, 1 if Yes with customers (BW compatible), 2 if Yes
with customers (BW compatible) and sub-suppliers.
Who pays for containers, what percent used? Standard size?
Custom?
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MC7 Is nonconforming material identified, 0 1 2 Score= 0 if No or an informal system is used, 1 if Yes and non-
QS segregated, formally dispositioned, and conforming material is effectively identified and segregated,
appropriate action taken to prevent recurrence? disposition is per formal procedure and is properly documented,
2 if criteria for 1 is met and corrective action is initiated to prevent
recurrence, effectiveness of corrective action is monitored for
effectiveness
*
MC8 Does the supplier have a formalized inventory 0 1 2 Score= 0 if No, 1 if Yes and an inventory allocation and tracking
management process? system exists (manual supermarkets, kanban, cycle counts, etc.)
2 if inventory is tracked at all stages (raw, WIP, finished goods)
What is your current inventory level in turns? and formal inventory planning exists, such as ABC analysis,
Last year? inventory stratification processes, and an active inventory
This year? reduction program. Consignment matl. is used where applicable.
20 turns is considered world class.
Look for balance in the amount of safety stock compared to
business conditions.
MC9 Does the supplier have a formal process 0 1 2 Score= 0 if No, 1 if Yes and information is reviewed prior to add-
QS for processing customer orders? ing to a planning system to determine material availability, capacity
availability, and final product availability before acknowledgement
of order or changes occur. Manual system acceptable (e.g.,
spreadsheet). 2 if yes and order process is a module integrated
in a requirements planning system, modular planning system, and
integrated with EDI transactions.
MC10 Does the supplier have a formal materials 0 1 2 Score= 0 if No, 1 if Yes and BOM's and manufacturing routings
planning process? exist for products, 2 if yes and standards are compared to actuals
and used for continuous improvement in the areas of Quality, Cost
& Delivery
MC12 Does the supplier have a formal capacity 0 1 2 Score= 0 if No or less than a 30 day horizon exists, 1 if Yes and
planning process? tied to customer orders and forecasts for at least 12 months, 2 if
yes and medium-term (1-3 years) and long-term (>3 years) plans
are developed, and include internal individual work center capacity
analysis and external sub-contractor and supply base capacity
analysis, and the completion of a manufacturing plan which
includes manufacturing flexibility capacities and an inventory plan
based on customer requirements.
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Production Systems *
Quality
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*
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Q1 Are boundary samples available to operators? 0 1 2 Score= 0 if No, 1 if Yes but limited application, 2 if Yes &
available at operation where applicable, samples show hi and lo
limits of acceptability, are in calibration system and are signed
off by leadership.
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Q2 Are appropriate gauges available at each 0 1 2 Score= 0 if No, 1 if Yes, 2 if Yes & operator instructions specify
workstation? how and where to gauge and/or automatic gauging is widely utilized.
Q4 Are Statistical methods used for Process 0 1 2 Score= 0 if No, limited or inappropriate use, 1 if Yes & procedure
QS Control? documented and data collected, 2 if Yes, documented, operator
involved and evidence exists of reaction to out of control/trends.
Charting: X, R, P. Talk to operator about training, how they use,
benefits seen. Procedures which control the application of
statistical techniques are documented? Poka-Yoke?
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Q6 Does the supplier have documented routings? 0 1 2 Score= 0 if No, 1 if Yes or if process is simple and obvious
and included in work instructions, 2 if routings exist and are rev.
level controlled.
Do routings describe process flow?
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Q7 Is mistake proofing part of process design? 0 1 2 Score= 0 if Error proofing is random, missing entirely or can be
circumvented by the operator. Learning is not cascaded to
similar processes. 1 if error proofing occurs after an issue is
identified. PFMEA is updated and error proofing is cascaded to
similar processes on the floor. Error proofing can not be
circumvented by the operator. 2 if error proofing is proactive.
PFMEAs are used to determine where error proofing must be
used and error proofing is cascaded to similar processes on the
floor. Error proofing can bot be circumvented by the operator.
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Setup Practices *
top
SP1 Are setup procedures documented? 0 1 2 Score= 0 if No, 1 if Yes, 2 if Yes w/visuals and evidence exists
that goals are established for set-up reduction, SMED (Single
Minute Exchange of Dies) is practiced as outlined in procedures.
Verify average set-up times.
SP2 Is there a process for managing and 0 1 2 Score= 0 if No or informal system, 1 if Yes, regularly cleaned
maintaining BW tooling? and properly identified, 2 if Yes and formal system exists for PM
with evidence that is utilized and effective.
Look for BW Brass Tag.
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SP3 Are tool life studies performed on perishable 0 1 Score= 0 if No or based on wear-out, 1 if Yes and evidence exists
tooling, e.g., drill bits, inserts? that it is utilized.
When? Ideally, tool life studies would be performed during the initial
process design stage prior to turning process over to pro-
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F2 Is the work environment suitable for the job 0 1 2 Score= 0 if No, 1 if Yes - cleanliness, lighting, and space utilization
performed? are appropriate for application. 2 if a formal 5S program has been
implemented.
Has the supplier incorporated human factors/ergonomics in
design of work functions? Is automation, such as "pick & place"
or robotics used?
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Maintenance * top
M1 Does the supplier have a predictive and 0 1 2 Score= 0 if No or informal process exists, 1 if PM is
preventative maintenance (PM) program? scheduled and recorded but system needs improvement, 2 if
machines and processes have recorded history of periodic PM.
PM includes procedures and schedule. PM exists for machines,
tooling, dies, molds, etc. PM includes evaluation of dies fixturing
and tooling at the start of each production run and utilizes
appropriate checklists. Information on unplanned downtime is
used for PM planning. PM schedule used in production planning.
Uses predictive monitoring tools.
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M2 Do you measure planned and unplanned 0 1 2 Score= 0 if No, 1 if Yes and some measures are utilized, 2 if
maintenance? supplier utilizes a formal Overall Equipment Effectiveness (OEE)
program as outlined in procedures or work instructions.
OEE = availability x performance efficiency x quality rate
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DIT2 How does the supplier assure dimensional 0 1 Score= 0 if No formal method exists, 1 if Formal method
layouts are performed consistently? exists, including written instructions and automated measurement
programs.
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DIT3 Are outside calibrations and layout suppliers 0 1 Score= 0 if No, 1 if Yes and qualified by survey or lab
qualified before use? accreditation.
Is supplier on approved supplier list? See criteria for list.
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DIT4 Is there a documented Gauge Calibration 0 1 2 Score= 0 if No or not documented, 1 if Yes, with
QS System and evidence of NIST and Gauge Masters? procedures documented, 2 if documentation includes
at a minimum, gauge list, calibration schedule, work instructions,
masters identified, proof of training (technicians), calibration
records, and containment instructions for gauges found to be out
of calibration.
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DIT6 Are gauge Repeatability and Reproducibility 0 1 2 Score= 0 if No, 1 if Yes with example of part, 2 if Yes and part
(gauge R&R) studies performed routinely? of quality philosophy and used for CI with multiple examples.
Do they utilize production parts?
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MS2 Delivery and Customer Satisfaction 0 1 2 Score= 0 if No measure exists or informal, 1 if Yes and measures
QS are utilized or customer supplied reports, 2 if supplier has
established outgoing delivery measures as part of a formal
continuous improvement process and results evident.
If a current supplier, are PPM goals for quality and delivery met?
If not a supplier, demonstrate PPM perf. with a similar part?
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MS3 First run quality 0 1 2 Score= 0 if No measure exists or informal, 1 if Yes and basic
measures are utilized, 2 if supplier has established comprehensive
measures as part of a formal continuous improvement process
and results evident.
First Run = the ability to produce a product right the first time
from the complete process without additional repair, rework etc.
Measures include: process quality inspections, yield, hot test etc.
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MS4 Are measurements communicated to the 0 1 2 Score= 0 if No, 1 if Yes but communication is informal, 2 if Yes
QS workforce? & supplier performance is charted, posted, and evidence exists that
it is regularly reviewed with all employees.
Look for localized communication board, charts, etc.
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MS5 Are quality performance measurements 0 1 Score= 0 if No, 1 if Yes and evidence exists that quality measures
available at the operator level? for work area, line, and machine/station are regularly shared with
all employees
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MS6 Have you benefited from your continuous 0 1 Score= 0 if No, 1 if Yes and documented results exist
improvement efforts? How? Documentation to include project plans, reports, etc. linked to
improvement trends.
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S3 Are you currently manufacturing and shipping 0 1 2 Score= 0 if No, 1 if Limited, 2 if Culturally engrained through
JIT to any customers? quality plan or similar document.
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S4 Do you use Electronic Data Interchange with 0 1 2 Score= 0 if No, 1 if Yes, 2 if exchanged EDI documents w/ BW
your customers? Transactions? Advance Ship Notice, Matl Rel, Ship,
and Purchase Order?
S5 Do you use bar code labeling with your 0 1 2 Score= 0 if No, 1 if Yes and has capability to work with BW,
customers? 2 if Labels have been rcv'd/aprvd by BW.
AIAG Standard bar code labeling.
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Review an EXAMPLE of Product and/or Process Development with a customer.
Indicate design of product or design of process here. (circle one or both) top
D2 Are design inputs identified, 0 1 Score= 0 if No, 1 if Yes
documented, and reviewed? Are all statutory and regulatory requirements considered? Is
contract review utilized to determine requirements? Are
ambiguous or conflicting requirements resolved?
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D3 Is design output adequate (verification)? 0 1 Score= 0 if No, 1 if Yes
Does the output meet the input requirements, contain
acceptance criteria, and identify critical characteristics?
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D4 Are design changes identified? 0 1 Score= 0 if No, 1 if Yes
Are changes documented? Are they reviewed and
approved by the appropriate individuals?
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D5 Are designs validated? 0 1 Score= 0 if No, 1 if Yes
Does validation demonstrate that the product conforms to the
defined user needs?
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D7 After a project has begun, are scheduled 0 1 Score= 0 if No, 1 if Yes
formal continuous improvement reviews held? Are records maintained? Do records show participation of all
affected functions? Do records demonstrate adequate design
verification activities?
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D10 Are you presently performing DFM/A on 0 1 2 Score= 0 if No, 1 if Yes informal , 2 if Yes with documented
designs? example of use in process development.
(Design For Manufacturing and Assembly)
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D11 Do you perform Design FMEA's ? 0 1 2 Score= 0 if No, 1 Yes Informal, 2 Yes with documented example.
Design Failure Mode Effects Analysis.
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D12 Do you apply Geometric 0 1 Score= 0 if No, 1 if Yes
Dimensioning/Tolerancing?
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Research and Development *
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D13 Are resources available for R&D? N Y N if No, Y if Yes
What capabilities are available ?
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What growth plans and new expertise are being
considered?
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D14 Is R&D a budgeted item? 0 1 2 Score= 0 if No, 1 if Yes - indirectly (resources provided but no
retn line item in budget), 2 if Yes - directly (line item in budget).
What percent of sales is the R&D budget? % What is the benchmark for their industry?
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D16 Has supplier participated in establishing 0 1 Score= 0 if No, 1 if Yes
test criteria? Ask to see an EXAMPLE where supplier worked with customer.
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D17 Are resources available for product life I E I if Internal, E if external
testing? Reliability, Durability, Performance in-house capability?
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D18 Are procedures available for tracking these I E I if Internal, E if external
activities?
Describe:
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Prototype Support *
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D19 Are resources available to produce models ? I E I if Internal, E if external
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QS2 What problem solving process does the 0 1 2 Score= 0 if None, 1 if informal process, 2 if Formal process with
supplier follow when performing corrective evidence (8D, Cause & Effect, & Etc.)
actions?
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QS3 Does the supplier have a formal procedure for 0 1 2 Score= 0 if not analyzed, 1 if Informal system, 2 if documented
analyzing customer returned product? system includes method for improvements based on returns
and/ or internal findings.
Ask about process or engineering changes based on
returns/warranty?
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QS4 Does corrective action system include: 0 1 2 Score= 0 if No or no evidence of use, 1 if Yes w/ doc procedure,
QS Customer complaints/returns, investigation 2 if Yes & part of Continuous Improvement.
of cause, determination of needed action, BW corrective action system must be traceable (internal/external).
and application of controls to ensure Is the activity appropriate in relation to risks; are all process
effectiveness of corrective action? changes due to corrective/preventative actions documented?
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QS5 Is preventative action utilized? 0 1 2 Score= 0 if No formal preventative action, 1 if Corrective action
applied to other areas, 2 if based on process analysis
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QS6 Does supplier have a process to notify the 0 1 2 Score= 0 if no recall system, 1 if customer is notified that suspect
QS customer when suspect material has been material has been released, 2 if lot number of suspect
shipped? material is provided to the customer.
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QS8 Does upper management regularly review the 0 1 2 Score= 0 if no review, 1 if management reviews documented,
quality system to determine its effectiveness? 2 if action plans are developed based on reviews.
QS9 Is there an internal audit function to verify 0 1 2 Score= 0 if no internal audit function, 1 if internal audits with
quality system effectiveness? documentation, 2 w/ evidence of mgmt review.
Including: Documentation, auditors independent of audited
area, corrective actions based on results, follow-up audits.
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QS10 Is there a documented system for 0 1 2 Score= 0 if no contract review or informal process utilized, 1 if
contract (PO) review prior to acceptance evidence exists that reviews are per documented procedure and
of an order? are effective, 2 if records show changes approved by relevant
functions.
Review ensures all requirements are adequately specified,
any discrepancies are resolved, and that capability to meet
requirements exists.
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QS11 Does the supplier's internal and customer metric 0 1 2 Score= 0 if No data, or metrics show no improvement
show that the supplier has been successful in 1 if Metrics show improvement, but below average in meeting
striving for a 0 defect methodology? targets. 2 if Metrics show improvement, and above average in
meeting targets.
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Purchasing System
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*
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PS1 Are requirements formally communicated 0 1 2 Score= 0 if communicated verbally, 1 if communicated
to sub-suppliers? (Tier II, III and so on?) by PO, 2 if PO's reviewed for adequacy before release.
Look for details on PO's in file
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PS2 Are criteria for selection, evaluation & 0 1 2 Score= 0 if no formal evaluation, 1 if evaluation of quality
re-evaluation of suppliers established & system through on-site visit or mail-in survey,
utilized? 2 if several documented on-site evaluations.
Evaluation should be at supplier's facility.
Does evaluation include all elements of ISO?
'Certify' by establishing mutual expectations for quality,
quantity, and delivery. Are approved suppliers documented?
PS4 Does the supplier have APQP for incoming parts 0 1 Score= 0 if AIAG or equivalent APQP requirements are not used
from sub-suppliers (Tier II, III and so on) as appropriate? on required incoming parts from sub suppliers. 1 if AIAG or
equivalent APQP requirements are used to validate incoming parts
from sub-suppliers (where required).
PS5 Does the supplier have PPAP for incoming parts 0 1 Score= 0 if AIAG or equivalent PPAP requirements are not used
from sub-suppliers (Tier II, III and so on) as appropriate? with all incoming parts from sub-suppliers. 1 if AIAG or equivalent
Annual Review of compliance? PPAP requirements are used to validate incoming parts from
sub-suppliers.
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PP2 Are machine/process capability studies 0 1 2 Score= 0 if No, 1 if Yes & documented, 2 if Yes & example
QS performed? When? By whom? Ask to see example.
PP3 Is PPAP understood and used? Example 0 1 2 Score= 0 if No or SIR only, 1 if Yes, 2 if Yes w/example
PP4 Does supplier have a process to identify 0 1 2 Score= 0 if No, 1 if key characteristics are defined and
key/special characteristics and pass through? and communicated via FMEA and Control Plan,
2 Supplier develops and documents special characteristics via
FMEA and Control Plan.
Ask to see examples of control plans w/ Key Characteristics.
PP5 Are all process changes documented and 0 1 2 Score= 0 if Not documented & not traceable, 1 if all changes
QS traceable? documented, 2 if documented and traceable to the employee.
PP6 Is there a system to inform customers of all 0 1 2 Score= 0 if Not informed prior to change, 1 if customer
QS process changes PRIOR to making change? informed before change takes effect, 2 if customer provided
analysis of cost/lead-time/quality/capacity benefits
before change takes effect. Look for e-mails, letters, and etc.
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PP7 Who is involved when determining process 0 1 2 Score= 0 if Manufacturing only, 1 if Quality and manufacturing,
changes prior to release for production? 2 if Quality and manufacturing with sign-off sheet per procedure.
Today it is acceptable for a manufacturer to have "everyone
responsible for quality." A plant that truly embraces this
philosophy would be very proactive. 2 points could be awarded
to this type of supplier. Be sure that this supplier weighs the
quality impact of the change on the supply chain and has some
evidence of this review before awarding the 2 points.
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PP8 Does the supplier and/or its sub-suppliers 0 1 2 Score= 0 if no, 1 if have evidence of compliance, 2 if have evidence
conform to CQI-9 Heat Treatment standard if applicable? of 3rd party assessment
Commitment to JIT/EI/CI
Poor Fair Good Very Good Excellent
Commitment to SPC
Poor Fair Good Very Good Excellent
Commitment to EDI
Poor Fair Good Very Good Excellent
Advanced Product Quality Planning Advanced Product Quality Planning (or APQP) is a framework of procedures
(APQP) and techniques used to develop products in industry, particularly the automotive
industry.
Audit Finding Major deficiency found in required element or quality system. Development
of action plan within agreed upon time period is required (normally 30 days).
Lead Purchasing Representative is responsible for follow-up of action plan
to assure completion by supplier. On-site re-survey may be required for
upgrade of supplier status.
All 'Critical' deficiencies are 'Findings' requiring an Action Plan.
Audit Concern or Observation Minor deficiency in required element or quality system. Action plan not
required, although it may be desirable. [ A lack of attention to a concern or
observation may result in a finding at a later date.]
Benchmark A set of measurements that is used to establish goals for improvements
in processes, functions, products, etc. Benchmark measures are often
derived from other firms that display "best in class" achievement.
Bar Code A series of bars and spaces printed on a label which can be read by
and input to a computer for timely and accurate data collection.
Computer-aided design (CAD) Computer-aided design is the use of computer technology to aid in the
design of a product.
CoA Certificate of Analysis - material or product certification which includes
analysis data.
CoC Certificate of Conformance (or Compliance) - suppliers affidavit that the
product is good.
Consignment Material Material which is owned by a supplier and the inventory is replenished by that
supplier.
Continuous Improvement (CI) Continuous improvement is an ongoing effort to improve the quality of
products, services or processes.
Cpk A measurement which provides information about process targeting and
variation relative to engineering specification. A measure of capability.
D&B Rating Short for Dunn & Bradstreet. A service which collects data relative to
financial and business indicators.
Design for Manufacturability & Assembly The process of designing a product so that it can be produced and
Electronic Data Interchange (EDI) Electronic exchange of documents such as purchase orders,
shipment authorizations, advance shipment notices, etc.
Employee Involvement (EI) Training employees to use their experience, creativity and intelligence and
by treating them with respect, keeping them informed and including
them and their ideas in decision making activities.
Enterprise Resource Planning (ERP) Enterprise Resource Planning (ERP) systems attempt to integrate all data
and processes of an organization into a unified system. A typical ERP system
will use multiple components of computer software and hardware to achieve
the integration. A key ingredient of most ERP systems is the use of a unified
database to store data for the various system modules.
Failure Modes and Effects Analysis A technique to identify and prevent potential modes of failure. There
(FMEA) are two types: DFMEA - Design Failure Modes & Effects Analysis,
and PFMEA - Process Failure Modes & Effects Analysis.
First in First out (FIFO) A system to ensure old product is used prior to new.
First Pass Yield Output that is defect and error free divided by total output [good parts
plus repaired, reworked, and scraped parts]. This can be measured for a
machine, a process, an assembly line or the production process for the
plant as a whole. The objective is to eliminate wastes in the form of scrap,
rework, or repair by highlighting and eliminating the causes of these wastes.
Examples of this measure might be yield from a molding process, the final
inspection yield from a multi-step manufacturing process, or yield from an
assembly line before rework.
Formal or Formalized Plan For larger businesses (>100 employees) a detailed and controlled
plan shall be in place. This could be indicated in an employee handbook.
For smaller businesses (<100 employees) it may be acceptable to have
details outlined in a series of Company Memos or letters to employees
and should include an action plan with follow up.
Job Shops Job shops are typically small manufacturing operations that handle specialized
manufacturing processes such as small customer orders or small batch jobs.
Job shops typically move on to different jobs (possibly with different customers)
when each job is completed.
Key Product Characteristic (KPC) A product feature for which reasonable and foreseeable variation is likely
to significantly affect the product's reliability, durability, compliance with
standards and regulations, fit or function, and customer satisfaction.
SOC or 100% inspection required.
Key Control Characteristic (KCC) Those parameters in the process which ensure the KPC is
achieved, such as speeds, feeds, tooling, etc.
Material Requirements Planning (MRP) Material Requirements Planning (MRP) is a software based production
planning and inventory control system used to manage manufacturing
Manufacturing Resource Planning II Manufacturing Resource Planning II (MRP II) is defined by APICS as a method
(MRP II) for the effective planning of all resources of a manufacturing company.
Ideally, it addresses operational planning in units, financial planning in dollars,
and has a simulation capability to answer "what-if" questions and extension of
closed-loop MRP.
Mean Time Between Failure (MTBF) The ability to predict, using statistical methods, machine failure prior to
it's occurrence so steps can be taken to minimize impact.
Mistake Proofing Manufacturing or setup activity designed to prevent a process error from
resulting in a product defect. Example; if an operation has been missed
the next operation cannot be performed due to physical or electronic
safe guards.
National Institute of Standards and The National Institute of Standards and Technology is a federal technology
Technology (NIST) agency that develops and promotes measurement, standards, and technology.
Preventative Maintenance (PM) Preventive maintenance (PM) is defined as a program in which wear,
tear, and change are anticipated and continuous corrective actions
are taken to ensure peak efficiency and minimize deterioration.
Production Part Approval Process (PPAP) The Production Part Approval Process (PPAP) is used in the automotive
supply chain to establish confidence in component suppliers and their
production processes, by demonstrating that all customer engineering design
record and specification requirements are properly understood by the supplier
and that the process has the potential to produce product consistently meeting
these requirements during an actual production run at the quoted production rate.
Research and Development (R & D) Research and development refers to creative work undertaken on a
systematic basis in order to increase the stock of knowledge and
the use of this stock of knowledge to devise new applications.
Statistical Process Control (SPC) Statistical Process Control is an effective method of monitoring a process
through the use of control charts.
Tool Life Studies A statistical means of identifying tool change intervals prior to adversely
affecting process variation. (see Mean Time Between Failures)
Total Productive Maintenance (TPM) Preventive maintenance plus continuing efforts to adapt, modify and
refine equipment to increase flexibility, ensure equipment is always ready
to produce product to spec with minimum variation. Operator oriented.