Part & Process Audit: Summary

Supplier: Supplier contact name:

Plant/ Location: Position:
Address: Phone:
Email Address:

Supplier code: Fax:

Audit Date: Initial audit (new supplier):
Report number: Initial audit (existing supplier):
Auditor Name: Re-audit:

GENERAL SUPPLIER INFORMATION:

Quality System Certification: Valid until:
Environmental Sytem Certification ISO 14001: YES NO Valid until:
Does the supplier have product liability insurance: YES NO

SUPPLIERS QUALITY PERFORMANACE

Quality %: PPM: Logistic %: Summary: 0
Audited product(s)/ product group (s):

Suppliers participants TRW participants

Overall Audit Result %: 0.0% Overall Rating: C

Summary/ remarks:

Engineering assistance required: YES NO Next audit date:

Purchasing assistance required: YES NO

Supplier corrective action plan required by: YES NO Date:

Immediate containment actions required in case of critical concerns:
Critical Concern Containment actions Who When

Supplier Signature/ Name/ Date TRW Signature/ Name/ Date

Eavaluation & Asessment Matrix

Result % Rating Description
90 - 100 A MEETS REQUIREMENTS: Supplier process meets requirements for serial production.
80 - <90 AB MINOR NON-CONFORMANCE(S): Supplier allowed to ship serial production material with corrective action and containment.
SIGNIFICANT NON-CONFORMANCE(S): Minor non-conformances with no more than one major non-conformance. Requires corrective
60 - <80 B
action and containment.
MAJOR NON-CONFORMANCES(S): Supplier's process incapable of supporting serial production requirements. Corrective Action and
<60 C
containment required.
Rating can be downgraded when items with severe impact to quality are rated 0.
Date: 31 Aug 2005 442736514.xls; Cover Process Owner/Department:
Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 1 of 20 Ed Carpenter / VP Purchasing
 Part & Process Audit: Results
Supplier: 0 Location: 0 Audit date: 30-Dec-1899 Report No.: 0

A APQP
Product Development

.1 .2 .3 .4 .5 .6 .1 .2 .3 .4 .5 Result 1,2 [%]

1 Planning 0 0 0 0 0 0 2 Realization 0 0 0 0 0 0%

Process Development

.1 .2 .3 .4 .5 .6 .1 .2 .3 .4 .5 .6 Result 3,4 [%]

3 Planning 0 0 0 0 0 0 4 Realization 0 0 0 0 0 0 0%

B Serial Production
.1 .2 .3 .4 .5 .6 .7 .8 .9 Result 5 [%]
5 Suppliers/ Material 0 0 0 0 0 0 0 0 0 0%

6 Production
6,1 Personal/ Qualification 6.2 Production Material/ Equipment 6.3. Transport/ Handling 6.4 Fault analysis/ corrective actions
.1 .2 .3 .4 .5 .1 .2 .3 .4 .5 .6 .7 .1 .2 .3 .4 .5 .1 .2 .3 .4 .5 .6
Process 1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P1 0%
Process 2
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P2 0%
Process 3
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P3 0%
Process 4
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P4 0%
Process 5
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P5 0%
Process 6
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P6 0%
Process 7
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P7 0%
Process 8
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P8 0%
Process 9
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P8 0%
Process 10
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 P10 0%
6,1 Personal/ Qualification 6.2 Production Material/ Equipment 6.3. Transport/ Handling 6.4 Fault analysis/ corrective actions

.1 .2 .3 .4 .5 .1 .2 .3 .4 .5 .6 .7 .1 .2 .3 .4 .5 .1 .2 .3 .4 .5 .6 P1-P10 [%]
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0%
Total [%] 0% Total [%] 0% Total [%] 0% Total [%] 0%

.1 .2 .3 .4 .5 Result 7 [%]
7 Final Inspection & Testing/ Customer service/ Concern Performance 0 0 0 0 0 0%

Overall result [%]: 0.0%

7 Final inspection/ customer service Process 10

6.4 Production - Fault analysis Process 9

6.3 Production - Transport/ Handling Process 8

6.2 Production - Material/ Equipment Process 7

6.1 Production - Personnel Process 6

5 Supplied Material Process 5

Process Validation Process 4

Product Validation Process 3

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Process 2

Process 1

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

10 Full Compliance/Performing Well

8 Predominant Compliance: Minor non-conformities - Requires Action Plan
6 Partial Compliance: Severe non-conformities - Requires action plan and containment
4 Unsatisfactory Compliance: Major non-conformances - Requires action plan and containment
0 No Compliance: Requires Action Plan and containment.
NR Not rated/ Not relevant

Date: 31 Aug 2005 442736514.xls; Results Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 2 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

1.0 Element: Product Development Planning Audit Worksheet

No. Question Evidence Required Look For Status Observations
1.1 Are the customer requirements ● Drawings, standards, specifications, performance specification; ●TRW requirements known and up to date
available? ● Logistic concepts; ▪ Product specifications
●Technical specifications, test specifications; ▪ Significant characteristics
● Quality agreements, target agreements; ▪ GSQM requirements
● Important product/process characteristics; ▪ Packaging/ Logistic requirements
● Purchase order documents with parts lists and delivery dates; ▪ Project timing and milestones
● Legislation/Directives; ● Legal/ environmental requirements known and up to date.
● Waste management plans, environmental aspects ● Documents are contolled, updated and distributed to the relevant
functions in case of modifications.

1.2 Is a product development plan ● Customer requirements ● A product development plan has been compiled and is it linked to
available and are the targets ● Costs the overall project plan.
maintained? ● Milestones: Planning/Purchasing release, modification stoppages ● The development plan includes TRW milestones, timing schedules
● Prototype/Pilot production, start of serial production and deliverables.
● Resources studies ● Progress is tracked and reviewed by management.
● Setting and monitoring the target ● Design reviews are planned and executed.
● Regular information to the company management ● Design verification test requirements and timing is included in the
● Simultaneous Engineering Teams (SET). plan.
● The test plan matches the TRW specifications.
● Product development plan
● TRW Specifications, drawings and program timing.

1.3 1.3 Are the resources for the ● Customer requirements ●Identification and planning of resources needed for product
realisation of the product development ● Qualified personnel development.
planned? ● Lost time through absenteeism ▪ Personnel
● Through put/Processing times ▪ Design facilities
● Buildings, premises (for trial/prototype construction) ▪ Prototype/ manufacturing facilities
● Tools/Equipment ▪ Inspection & test facilities.
● Test/Inspection/Laboratory equipment
● CAD, CAM, CAE

1.4 Have the product requirements been ● Customer requirements ● Reliability targets defined.
determined and considered? ● Company objectives ● Historical problems, concerns and corrective actions taken into
● Simultaneous Engineering consideration.
● Robust design/safe process ● The suppliers drawings,specifications, and all other related
● Regular customer/supplier meetings requirements match TRW requirements.
● Special characteristics, legislation requirements
● Functional measurements
● Fitting measurements- Material.

1.5 Has the feasibility been determined ● Design/Engineering ● A feasibility study has been completed.
based on the available requirements? ● Quality- Process equipment, resources ● The feasibility committed to TRW.
● Special characteristics ● Feasibility is re-evaluated for all product modifications.
● Company objectives
● Directives, standards, legislation
● Environmental aspects
● Delivery dates/Time frames
● Cost frame

Date: 31 Aug 2005 442736514.xls; E1.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 3 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

1.0 Element: Product Development Planning Audit Worksheet

No. Question Evidence Required Look For Status Observations
1.6 Are the necessary personnel and ● Project management, project planning team/responsibilities ● A cross functional project team been created.
technical conditions for the project ● Qualified personnel ● The members sufficiently qualified.
process planned/available? ● Communication means (Electronic data transfer) ● The team contacts have been communicated to TRW.
● Information flow from and to the customer during planning (regular ● Progress is regulary communicated to TRW ( APQP tracking,
meetings, conferences) project plan updates and related detail reports).
● Tools/equipment
● Test/inspection/laboratory equipment
● CAD, CAM, CAE.

Date: 31 Aug 2005 442736514.xls; E1.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 4 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

2.0 Element: Realizing Product Development Audit Worksheet

No. Question Evidence Required Look For Status Observations
2.1 Is the design FMEA raised and are ● Customer requirements/performance specifications ● A cross functional team creates the FMEA.
improvement measures established? ● Function, safety, reliability, maintainability, important characteristics ● Historical concern data has been considered.
● Environmental aspects- Involvement of all affected areas ● Significant and critical characteristics are identified and made part
● Trial and test results of the document.
● Product-specific measures from the process FMEA ● Appropriate corrective actions are documented and implemented
for design characteristics with high RPN and/or high severity ranking.

2.2 Is the Design FMEA updated in the ● Customer requirements ● The FMEA is reviewed and updated in case of product
project process and are the ● Important parameters/characteristics, legal requirements modifications.
established measures realized? ● Function, fitting measurements ● The FMEA is updated based on feedback from product validation
● Material- Environmental aspects concerns and results.
● Transport (internal/external) ● Corrective actions are completed and verified.
● Product-specific measure from the Process FMEA

2.3 Is a control plan prepared? ● Establishment and marking of significant characteristics ● The quality plan maintained and up to date.
● Creation of an inspection and test plans ● The quality plan lists all tests and inspections.
● Provision for equipment, tooling and fixtures ● Manufacturing and inspection instructions are clearly linked.
● Timely, planned provision of measuring equipment ● All process and control points are accuractely detailed.
● Inspections at appropriate points during the production ● The control plan includes supplied materials and sub-contracted
● Clarification of acceptance criteria processes.
● The control plan includes all designated characteristics.

2.4 Are the required releases/qualification ● Product trials (e.g. fitting inspections, functional tests, durability ● The design is sufficiently qualified and the results are properly
records at the respective times ? checks, environmental simulations) documented.
● Status of the prototype parts ▪ DV-test results
● Pilot series model- Production/inspection, measuring and test ▪ Manufacturing and assembly trials
equipment in experimental installation ▪ Qualification of sub-contracted components
▪ Inspection and test equipment
● The qualification results are obtained from production intent parts?
● Appropriate corrective actions are in place for non-conformances
encountered.
● Corrective actions, for non-conformances, are documented in
concern and corrective actions reports (8D-reports).
● The corrective actions include verification to confirm the
effectiveness of the actions.

2.5 Are the required resources available? ● Training Records ● Customer requirements
● Qualified personnel ● Qualified personnel
● Attendence Reports ● Lost time through absenteeism
● Capacity Studies ● Through put/Processing time
● Floorplans ● Buildings, premises- Experimental installation
● Prototype process/procedure ● Prototype construction
● Tools/Equipment
● Test/Inspection/Laboratory equipment.

Date: 31 Aug 2005 442736514.xls; E2.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 5 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

3.0 Element: Process Development Planning Audit Worksheet

No. Question Evidence Required Look For Status Observations
3.1 Are the product requirements ● Customer requirements ● All TRW specifications available and up to date:
available? ● Legislation, standards, directives- Logistic concepts ▪ Product specifications
● Technical specifications- Quality/target agreements ▪ Significant characteristics
● Important characteristics- Material ▪ GSQM requirements
● Waste management plans, environmental aspects. ▪ Packaging/ Logistic requirements
▪ Project timing and milestones
● The specifications to the latest revision level.
● Legal/ environmental requirements known and up to date.
●The documents controlled, updated and distributed to the relevant
functions in case of modifications.

3.2 Is a process development plan ● Customer requirements ● Has a project timing plan been compiled?
available and are the targets ● Costs ● Does the timing plan meet TRW milestones, timing schedules and
maintained? ● Milestones: Planning/Purchasing release, Prototypes/pilot deliverables?
productions, Start for serial production. ● Does the project plan include TRW required APQP elements?
● Resources studies. ● Is the timing plan regulary reviewed and updated?
● Provision of production/testing equipment, software, packaging. ● Are the updates communicated to TRW?
● Contingency plans for catastrophic issues (start-up problems, natural ● Does the project plan include backup solutions/ safe launch
disasters, unavailable raw materials and components, etc.) activities?
● Packaging and logistics/delivery concepts. ● Does the project plan include detailed planning for manufacturing
● Setting and monitoring the targets for deliverables. equipment and tooling?
● Scheduled management reviews. ● Does the project plan include detailed planning of sub-contracted
components?
● Is the APQP progress tracked and regulary reported to TRW if
required?
● Is TRW immediately informed in case of delays/ problems?

3.3 Are the resources for the realization of ● Customer requirements- Availability of input material ● Are the resources needed for process development and serial
serial production planned? ● Qualified personnel production identified and planned?
● Lost time through absenteeism/Standstill times ▪ Personnel· Production facilities
● Through put times/Processing times/No. of production pieces per ▪ Transport/ handling facilities
plant/Equipment- Buildings, premises · Inspection & testing facilities
● Plants, tools, production/testing equipment, auxiliary tools, laboratory ▪ Analysis/ diagnosis facilities
equipment
● Transport means, containers store

3.4 Have the process requirements been ● Customer requirements ● Are the requirements to the manufacturing process determined?
determined and considered? ● Legislative requirements ● Has a process flow chart been prepared?
● Capability records ● Are part and process validation plans in place to qualify production
● Suitability of plants, tools, inspection and test equipment parts & processes?
● Arrangement of work an inspection stations ▪ Production validation testing
● Handling, packaging, storage, marking. ▪ Capability studies
▪ Measurement system/ gauge R&R studies
▪ Packaging/ transport approval· Volumes/ demands
● Are historical problems/ concerns & corrective actions taken into
consideration?
● Are PPM-targets defined?
● Is the manufacturing & quality concept communicated to TRW and
approved?
● Has a feasibility study been completed?
● Is the feasibility committed to TRW ?
● Has a forcasted capacity verification been compiled and is it
submitted to TRW ?

Date: 31 Aug 2005 442736514.xls; E3.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 6 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

3.0 Element: Process Development Planning Audit Worksheet

No. Question Evidence Required Look For Status Observations
3.5 Are the necessary personnel and ● Project management, project planning team/responsibilities ● Has a cross functional project team been appointed and are the
technical preconditions for the project ● Qualified personnel members sufficiently qualified?
process planned / available? ● Plants, tools, production/testing equipment, auxiliary tools, laboratory ● Are the contacts been communicated to TRW?
equipment ● Is the progress regulary communicated to TRW if required (APQP
● Communication means (e.g. electronic data transfer) tracking, project plan updates and related detail reports)?
● Information flow from and to the customer during the planning
(regular meetings, conferences)
● CAD, CAM

3.6 Is the process FMEA raised and are ● All production stages, including those of suppliers ● Is the FMEA prepared in teamwork?
improvement measures established? ● Customer requirements ● Have historical concern data been reviewed?
● Function ● Have significant characteristics and process parameters been
● Important parameters/characteristics identified?
● Traceability ● Have appropriate actions been planned for high RPN and/or high
● Environmental aspects severity ranking?
● Transport (internal/external) ● Does sequence of PFMEA match production flow chart and control
● Involvement all affected areas plan?
● Process-specific measures from the design FMEA

Date: 31 Aug 2005 442736514.xls; E3.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 7 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

4.0 Element: Realizing Process Development Audit Worksheet

No. Question Evidence Required Look For Status Observations
4.1 Is the process FMEA updated when ● Customer requirements ● Is the FMEA reviewed/ updated in case of product/ process
amendments are made during the ● All production phases, including those of suppliers modifications?
project and are the established ● Important parameters/characteristics ● Are part & process validation concerns & results fed back into the
measures implemented? ● Legislative requirements FMEA?
● Fitting measurements ● Have corrective actions been completed and verified?
● Material ● Are TRW designated characteristics considered sufficiently within
● Traceability the FMEA study.
● Environmental aspects
● Transport (internal/external)
● Process-specific measures from the design FMEA.

4.2 Is a control plan & process flow chart ● A comprehensive documentation of the product and process ● Is the control plan maintained and up to date?
prepared? characteristics, the process control measures, the inspection, test and ● Does the control plan itemise all tests & checks?
measurement systems which are to be considered during the pilot ● Are related working & inspection instructions clearly linked?
production phase, pre-launch phase (incl. addition safe launch ● Are all process and control points accuractely detailed?
activities), serial production.It must give details, amongst others, about: ● Does the control plan include supplied material and sub-contracted
▪ establishing and marking of significant characteristics processes?
▪ raising of an inspection and test plan ● Does the control plan highlight significant characteristics?
▪ provision of equipment and fittings ● Does the control plan match process flow chart?
▪ timely, planned provision of measuring equipment ● Does the control plan list agreed standards of acceptance for
▪ inspections at appropriate points during the production details not specified on the drawing?
▪ clarification of acceptance criteria. ● Are TRW designated characteristics part of the control plan and
highlighted, do these characteristics have sufficient control?
● Is a pre-launch control plan been prepared, have safe launch
activities been identified?

4.3 Are the required releases/qualification ● Product trials (e.g. fitting inspection, functional test, durability check, ● Are parts and processes sufficiently qualified?
records available at the respective environmental simulations) ▪ Production validation testing
times? ● Pilot production parts ▪ Dimensional results
● First sample ▪ Material results
● Capability records of important product/process characteristics ▪ Capability studies
● Logistic concept (e.g. checking suitability of packaging by a test ▪ Measurement system/ gauge R&R studies
dispatch) ▪ Packaging/ transport approval
● Tools, machines, equipment, inspection, measuring and test ● Is complete PPAP submission to TRW done according GSQM150?
equipment ● Is PPAP submission done at the agreed timeline?
● Is PPAP approval obtained from TRW prior to production start?
● Are the results obtained from representative PPAP production run/
Parts produced out from serial process?
● Have the sub-contracted parts full PPAP approval?
● Are non-conformities/ deviations from specifications approved by
TRW prior to PPAP submission (Consession request)?
● Are the results properly documented and retained according to
GSQM?

4.4 Is a pre-production carried out under ● Customer requirements ● Are pre-production trial runs carried out to evaluate the production
serial conditions for the serial release? ● Establishing minimum numbers of production pieces readiness?
● Process capability analysis ● Are the results/ problems/ reject rates … monitored and fed back
● Measuring equipment capability into improvement plans?
● Readiness of the production materials and equipment for series ● Are the corrective actions followed up and is the problem resolution
(measuring records) verified?
● First sample inspection
● Handling, packaging, marking and storage
● Personnel qualification
● Work/Inspection instructions
● Arrangement of work/inspection stations

Date: 31 Aug 2005 442736514.xls; E4.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 8 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

4.0 Element: Realizing Process Development Audit Worksheet

No. Question Evidence Required Look For Status Observations
4.5 Are the production and inspection ● Process parameters (e.g. pressures, temperatures, times, speeds) ● Are the process parameters defined with limits?
documents available and complete? ● Machine/tool/auxiliary means data ● Are working and inspections instructions complete, maintained and
● Inspection requirements (important characteristics, inspection, up to date?
measuring and test equipment, methods, inspection frequencies) ● Do they carry an issue level?
● Intervention limits in process control charts ● Are acceptance standards/ visual aids complete?
● Machine and process capability records- Operating instructions ● Do all inspection instructions/ SPC charts … do have defined
● Work instructions acceptance criteria/ limits?
● Inspection instructions ● Are diagnosis/ rework instructions complete?
● Information on the current non-conformity ● Are set instructions complete?
● Are golden samples/ test facilities prepared to verify correct
function of poka yoke/ testing devices prior to production start?

4.6 Are the required resources available? ● Customer requirements ● Are all organizational measures complete in order to ensure a fault
● Availability of input material free production start? (i.e. material, training, production area,
● Qualified personnel equipment …)
● Lost time through absenteeism/Downtimes ● Has production readiness been assessed? (Production Readiness
● Through put times/Processing times/No. of production pieces per Audit / Run at Rate / GSQM 200)
plant/equipment
● Buildings, premises
● Plants, tools, production/inspection equipment, auxiliary tools,
laboratory equipment
● Transport means, containers, store.

Date: 31 Aug 2005 442736514.xls; E4.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 9 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

5.0 Element: Suppliers / Input Material Audit Worksheet

No. Question Evidence Required Look For Status Observations
5.1 Are only approved quality capable ● Supplier discussions/regular support ● Are the suppliers certified ISO 9000:2000 and/or TS16949:2002?
suppliers used? ● Evaluation of the quality capability e.g. audit results/certificates ● Are process audits carried out on the supply base?
● Assessment of the quality performance (quality/costs/service). ● In case of deficiencies are there corrective actions determined and
followed up?

5.2 Is the agreed quality of the purchase ● Sufficient inspection and test possibilities (Laboratory and measuring ● Are the quality requirements agreed with the supplier (drawings,
parts guaranteed? equipment) specifications, acceptance standards, significant characteristics,
● Internal/external inspections and tests testing methods …)?
● Supplied gauges/surveys ● Are the specification to the latest revision level?
● Drawings/order details/specifications ● Are adequate sampling plans in place?
● Quality assurance agreements ● Are results properly documented with sufficient detail and linked to
● Co-ordination of inspection and testing procedures, proceedings and material batches?
frequencies ● Do the results provide evidence of 0-defect/ process capability?
● Analysis of nonconformity focal points ● In case of non-conformities are containment and corrective actions
● Capability evidence. in place to provide 100% o.k. parts?

5.3 Is the quality performance evaluated ● Records about quality meetings ● Is the quality performance of suppliers monitored?
and are corrective actions introduced ● Agreements about and monitoring of improvement programs ● Are appropriate supplier development activities in place to improve
when there are deviations from the ● Inspection and measuring records of improved components quality performance?
requirements? ● Analysis of nonconformity focal points/problem suppliers.

5.4 Are target agreements for continual ● Workshops (interdisciplinary working groups) ● Is supplier performance measured against agreed targets?
improvement of products and process ● Establishing measurable target parameters for quality, price, service
made and implemented with the e.g.:
suppliers? ▪ Reducing the inspection and testing magnitude whilst raising
process safety
▪ Reducing rejections (internal/external)
▪ Reducing the stock in circulation
▪ Increasing customer satisfaction

5.5 Are the required releases for the ● Construction model, trial testing releases ● Do the supplied components have full PPAP/ ISIR approval to the
supplied serial products available and ● PPAP/ ISIR latest revision level?
the required improvement measures ● Capability evidence for important characteristics ● Is the PPAP/ ISIR documentation complete?
implemented? ● Consideration of the safety data sheets, EC guidelines ● Do product/ process modifications have PPAP approval?
● Reliability assessments ● Is a periodic product revalidation in place?
● Re-qualification inspection reports and the resulting improvement
measures.

5.6 Are the procedures agreed with the ● Control Plan ● Control, verification, storage, transport, maintenance of quality and
customer, regarding customer- ● Inspection Instructions properties
supplied products, maintained? ● Material Rejections ● Information flow, in cases of nonconformity or loss
● Communication to Customer, Supplier ● Quality documentation (quality status, quality history)
● Quality documentation

5.7 Are the stock levels of input material ● Customer requirements ● TRW volume requirements?
matched to production needs? ● KANBAN/Just in time ● Are backup plans in place in case of bottlenecks?
● Storage costs ● Are safety stocks in place in case of long/ risky supply chain?
● Emergency strategy when input material bottlenecks occur
● FIFO (firstin/first out).

Date: 31 Aug 2005 442736514.xls; E5.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 10 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

5.0 Element: Suppliers / Input Material Audit Worksheet

No. Question Evidence Required Look For Status Observations
5.8 Are input materials/internal residues ● Packaging ● Is the packaging, handling & storage or input material appropriate
delivered and stored according to their ● Storage administration system to protect from damage?
purpose? ● FIFO (first in/first out) ● Are climatic constraints, cleanliness requirements respected if
● Tidiness and cleanliness applicable?
● Climatic conditions ● Does the stock management ensure FIFO, traceability information
● Protection against damage/contamination and preventing from parts being mixed up?
● Identification (Traceability/Inspection status/Sequence of ● Does the stock management ensure, that non-conforming or
operations/Application status) obsolete material is not used?
● Safety against mix ups ● Is there a suitable quarantine area?
● Secure storage (fitted and used). ● Is rejected material traced to reason of rejection, date and
corrective actions?

5.9 Is the personnel qualified for the ● Personnel responsible for the following areas, for example, are to be ● Job Descriptions
respective tasks? considered: ● Training records
▪ Supplier selection, evaluation, qualification ● Cross Training
▪ Product inspection, measuring and testing
▪ Storage/Transport
▪ Logistics.Knowledge must be available, for example, about:
▪ Product/specifications/special customer requirements
▪ Standards/legislation
▪ Packaging
▪ Processing
▪ Evaluation methods (e.g. audits, statistics)
▪ Quality techniques (e.g. 8D-Method, Cause/Effect diagram)
▪ Foreign languages.

Date: 31 Aug 2005 442736514.xls; E5.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 11 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

6.1 Element: Personnel / Qualification Audit Worksheet

Process 10
Process 1

Process 4

Process 5

Process 7

Process 8

Process 9
Process 2

Process 3

Process 6
No. Question Evidence Required Look For Observations

Status

Status

Status

Status

Status

Status
Status

Status

Status

Status
6.1.1 Are the employees given responsibility ● Co-operation on improvement programs ● Is the personnel at manufacturing qualified to
and authority for monitoring the ● Worker self assessments monitor and judge product/ process quality?
product/process quality? ● Process approval/release ● Is the personnel prepared to take appriopriate
● Set up release(First/last production piece testing) actions in case of problems/ non-conformities?
● Process control (Interpretation of control charts)
● Authority to stop production.

6.1.2 Are the employees given responsibility ● Tidiness and cleanliness ● Is the production personnel tasked and qualified to
and authority for production ● Carrying out or ordering repair and maintenance take care of first level maintenance, cleanliness and
equipment and environment? work tideness at work places?
● Providing parts/storage ● Does the personnel have the necessary skills,
● Carrying out/ordering the installation and calibration authority and do they practice it?
of inspection, measuring and test equipment.

6.1.3 Are the employees suitable to perform ● Introduction/Training/Qualification records about the ● Is the personnel trained to perform the required
the required tasks and is their process tasks?
qualification maintained? ● Knowledge of the product and nonconformities ● Are there appropriate training plans against
which have occurred required qualifications in place?
● Instructions in health and safety at
work/Environmental aspects
● Instructions for the handling of “components with
special verification requirements”
● Qualification records (e.g. Welder certificates, sight
tests, driving license for industrial trucks).

6.1.4 Is there a personnel plan with a ● Shift plan (contract related) ● Is there a personnel planning which ensures that
replacement ruling? ● Qualification records (Qualification matrix) sufficiently trained personnel is available for each
● Work analyses/Time and motion studies. process step?
● Is there a skill matrix demonstrating all shifts are
trained sufficiently?

6.1.5 Are instruments to increase employee ● Quality information (Specified/Actual values) ● Does the supplier have a system of personnel
motivation effectively implemented? ● Improvement suggestions motivation and does it encourage people to improve
● Voluntary activities (Training courses, quality process?
circles) ● Incentive programs
● Low illness frequency rate ● Suggestion Box
● Contribution to quality improvement ● Posted communications
● Self assessments.

Date: 31 Aug 2005 442736514.xls; E6.1 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 12 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

6.2 Element: Production Material / Equipment Audit Worksheet

Process 10
Process 3

Process 6

Process 9
Process 1

Process 2

Process 4

Process 5

Process 7

Process 8
No. Question Evidence Required Look For Observations

Status

Status

Status

Status

Status

Status

Status

Status

Status

Status
6.2.1 Are the product-specific quality ● Machine/Process capability evidence important ● Is the manufacturing equipment in a condition and
requirements fulfilled with the characteristics/Process parameters maintained to provide stable quality?
production equipment/tools? ● Compulsory control/regulation of important ● Are 1st and 2nd level maintenance instructions in
parameters place, activities carried out to plan and documented?
● Warnings when deviations from specified values ● Is the manufacturing process capable and stable to
occur (e.g. lamps, sirens, shutdown) fullfill the quality requirements (cpk > 1,33)?
● Feed and delivery equipment ● Are process parameters defined and controlled to
● Maintenance and repair status of ensure stable production?
tools/plants/machines (including scheduled ● Does the process provide safe failure prevention/
maintenance) detection (i.e. poka yoke)?
● Does the process ensure, that nok/ suspect parts
are not slipping through?

6.2.2 Can the quality requirements be ● Reliability, function and corrosion resistance tests ● Are the required inspection & testing facilities in
monitored effective during serial ● Measuring accuracy/inspection, measuring and test place?
production with the implemented equipment capabilities ● Are they suitable to control the quality
inspection, measuring and test ● Data acquisition and analysis characteristics?
equipment? ● Calibration records. ● Are inspection & test facilities calibrated,
maintained?
● Do they have approved Measurement System
6.2.3 Are the work and inspection stations ● Work Stations ● Ergonomics
Study/ Gauge R&R?
appropriate to the needs? ● Inspection Stations ● Lighting
● Tidiness and cleanliness
● Environmental protection
● Surroundings/Handling of the components
● Health and safety at work.

6.2.4 Are the relevant details in the ● Process parameters (e.g. pressures, temperatures, ● Are clear, concise work & inspection instructions at
production and inspection documents times, speeds) each work station?
complete and maintained? ● Machine/tool/auxiliary means data (Tool and ● Are the instructions maintained and to the latest
machine numbers) revision level?
● Inspection requirements (important characteristics, ● Do they reflect concerns?
inspection, measuring and test equipment, methods, ● Are the instructions suitable and understandable?
frequencies) ● Are they assisted by visual aid where appropriate?
● Intervention limits in process control charts ● Are acceptance standards/ limits clearly defined?
● Machine and process capability records
● Operating instructions- Work instructions
● Inspection instructions
● Information on the current nonconformities.

6.2.5 Are the necessary auxiliary means ● Tooling plans ● Are all instructions and means available and
available for adjustments? ● Tool setting aids/comparison aids suitable to adjust and verify manufacturing
● Flexible tool change equipment equipment:
● Limits patterns. ▪ tooling plans,
▪ setting aids,
▪ master pieces,
▪ golden samples

Date: 31 Aug 2005 442736514.xls; E6.2 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 13 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

6.2 Element: Production Material / Equipment Audit Worksheet

Process 10
Process 3

Process 6

Process 9
Process 1

Process 2

Process 4

Process 5

Process 7

Process 8
No. Question Evidence Required Look For Observations

Status

Status

Status

Status

Status

Status

Status

Status

Status

Status
6.2.6 Is an approval for production starts ● New, changed product Are appropriate checks in place to ensure that all
issued and are adjustment details, as ● Downtimel of the equipment/process interruption relevant process and control means are o.k. and
well as deviations recorded? - Repair, tool change ready for production?
- Material change (e.g. Batch/heat change) Is there a first/ last piece inspection in place to verify
- Changed production parameters that quality requirements are met?
- First production piece testing with documentation Are all checks properly documented?
- Topicality of the parameters Is the function of the poka yoke and test devices
- Tidiness and cleanliness at the work station verified prior to start of production (e.g. golden
- Packaging sample)?
- Release / modification status of tools and
inspection, measuring and test equipment.

6.2.7 Are the required corrective actions ● Risk analyses (Process FMEA), Fault analyses ● Don non-conformities detected immediately lead to
carried out on schedule and checked ● Improvement programs from audits containment and corrective actions to prevent from
for effectiveness? ● Information to the responsible party parts being delivered?
● Interface discussions internal/externa ● Are suspect parts checked downstream?
● Internal complaints ● Are risks and internal/ external concerns recovered
● Customer complaints by appropriate corrective actions?
● Customer surveys.

Date: 31 Aug 2005 442736514.xls; E6.2 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 14 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

6.3. Element: Transport/Parts Handling/Storage/Packaging Audit Worksheet

Process 10
Process 1

Process 8
Process 2

Process 3

Process 4

Process 5

Process 6

Process 7

Process 9
No. Question Evidence Required Look For Observations

Status

Status

Status

Status

Status

Status
Status

Status

Status

Status
6.3.1 Are the quantities/production lot sizes ● Sufficiently suitable transport means ● Does the amount of parts in between the operations
matched to the requirements and are ● Defined storage areas not exceed the defined stock level?
they purposefully forwarded to the ● Minimal/no intermediate store ● Does the work flow and stock management support
next work station? ● KANBAN “one piece” flow (minimized stock levels)?
● Just in time ● Are parts in between the operations stored at the
● First in/first out dedicated locations?
● Storage administration ● Does handling of the parts ensure, that only o.k
● Modification status parts are proceeded to the next operation?
● Only transfer of satisfactory parts
● Recording production pieces numbers/evaluation
● Information flow.

6.3.2 Are products/components ● Stock levels ● Does internal transport, handling & storage ensure,
appropriately stored and are the ● Protection against damage that parts are not damaged?
transport means/packaging equipment ● Parts positioning ● Does it ensure cleanliness & tideness?
tuned to the special properties of the ● Tidiness, cleanliness, overstocking (storage areas, A● re environmental constraints (i.e climate control,
product/components? containers) storage time …) respected?
● Monitoring of the storage time
● Environmental influences, air conditioning.

6.3.3 Are rejects, rework and adjustment ● Holding store, holding areas ● Does the handling and processing of non-
parts, as well as internal residues ● Marked containers for rejects, rework parts and conforming parts ensure, that they can’t slip through?
strictly separated and identified? adjustment parts ● Are rejected parts properly identified & segregated
● Nonconforming products and nonconformity (Are they traced for reject reason, date and corrective
characteristics action)?
● Identification/marking ● Are appropriate reject bins at each work station?
● Defined transfer/rework stations in the production ● Is there an appropriate quarantine area?
department. ● Are reworked parts marked/ identified?
● Are reworked parts subject to re-inspection?

6.3.4 Is the material and parts flow secured ● Identification/Marking of parts ● Does the management of internal handling and
against mix ups / exchanged by ● Identification/Marking of the operational, inspection storage ensure that traceability is not lost?
mistake and traceability guaranteed? and test and application status ● Is the material correctly identified (p/n, rev. level,
● Batch/heat numbering WIP status; production date, batch number …)?
● Expiry date ● Does the internal material management ensure
● Removal of invalid identification/marking FIFO?
● Working documents with parts/production data.

6.3.5 Are tools, equipment and inspection, ● Preventive Maintenance procedure ● Storage without risk of damage
measuring and test equipment stored ● Gauge Identification and Calibration procedure ● Tidiness and cleanliness
correctly? ● Designated Storage areas ● Defined storage location
● Environmental control, when necessary ● Environmental influences
● Identification/Marking
● Defined release and revision status.

Date: 31 Aug 2005 442736514.xls; E6.3 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 15 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

6.4. Element: Fault analysis/Correction/Continual Improvement Audit Worksheet

Process 10
Process 1

Process 8
Process 2

Process 3

Process 4

Process 5

Process 6

Process 7

Process 9
No. Question Evidence Required Look For Observations

Status

Status

Status

Status

Status

Status
Status

Status

Status

Status
6.4.1 Are quality and process data recorded ● SPC Charts ● General charts
complete and ready to be evaluated? ● Inspection Instructions ● Nonconformity lists
● Manufacturing Instructions ● Control charts
● Control Plans ● Data acquisition
● Records of process parameters (e.g. temperature,
time, pressure)
● Plant downtime
● Parameter changes
● Power cuts.

6.4.2 Are the quality and process data ● SPC ● Process capabilities
statistically analyzed and are ● Pareto Analysis ● Failure modes/failure frequencies
improvement program derived from ● Cause/effect diagrams. ● Nonconformity costs
this? ● Process parameter
● Rejects/rework
● On hold notifications/Sorting actions
● Cycle, through put/processing times
● Reliability/Failure conduct.

6.4.3 Are the causes of product and ● Material review process/procedure ● Additional dimensional, material, functional,
process nonconformities analyzed and ● Internal Corrective Actions endurance tests
the corrective actions checked for their ● Non-conforming material control process/procedure ● Cause/effect diagram
effectiveness? ● PFMEAs ● Taguchi, Shainin
● Control Plans ● FMEA/Fault analysis
● Process capability analysis
● Quarantine area
● Quality Circle
● 8D-Method.

6.4.4 Are processes and products regularly ● Completed audits ● Customer requirements
audited? ● Corrective actions based on audit results ● Important characteristics
● Management review of audit results ● Function
● Internal audit schedule ● Process parameters/capabilities
● Marking/identification, Packaging
● Established processes/procedures.

6.4.5 Are product and process subject to ● Continuous Improvement Process ● Cost optimization
continual improvement? ● Periodic management reviews regarding ● Reduction of waste (e.g. rejects and rework)
continuous improvement ● Improving of process safety (e.g. process analysis)
● Kaizan events ● Optimizing set-up times, raising plant availability
● VA/VE teams ● Reducing through-put/processing times
● Reducing stock levels.

6.4.6 Are target parameters available for ● Production targets ● Personnel attendence records/trends
product and process and is their ● OEE metrics ● Number of production pieces produced
compliance monitored? ● QOS targets and charts ● Quality indices (e.g. failure rates, audit results)
● Scrap rates ● Through-put/processing times
● Nonconformity costs
● Process characteristic values (e.g. process
capability).

Date: 31 Aug 2005 442736514.xls; E6.4 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 16 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

7.0 Element: Customer Service, Customer Satisfaction, Service Audit Worksheet

No. Question Evidence Required Look For Status Observations

7.1 Are Customer Requirements Fulfilled ● Quality agreements ● Does manufacturing & control, do acceptance
at Delivery? ● Dispatch audits standards and limits match TRW requirements and
● Endurance testing (Investigating failure conduct) specifications.
● Storage/Call off processing/parts provision ● Do checking & testing methods match TRW
/dispatch requirements and specifications.
● Functional testing ● Does the control of designated characteristics
● Suitability of inspection, measurement and test match the agreed requirements
equipment ● Do parts identification, packaging & labelling match
● Agreed inspection and testing procedures TRW requirements.
● Topicality of the specifications. ● Is the product re-qualified min on an annual basis.
● Are the results properly documented and retained
to GSQM.

7.2 Is Customer Service Guaranteed? ● Records of customer visits, if necessary, deriving ● Are contacts and required information maintained in
measures the TRW VIN system, including
● Knowledge of product application- Knowledge of ▪ Company management
product problems ▪ Quality contact
● Implementation of new requirements ▪ IMDS/ELV Coordinator
● Notification of product/process ▪ ISO/TS 16949 Certification information, copy of
changes/redeployments, (also of suppliers) certificate
● First/repeat samplings (Trial/Series) ● Is TRW informed in writing before any product/
● Information about nonconformities. process modifications?
● Is PPAP approval obtained prior to introduction to
serial deliveries?
● In case of deviations is TRW informed with enough
time to process?
● In case of concession request is TRW approval
obtained prior to PPAP submission/ part delivery?
● Are corrective action plans (i.e. APQP, Parts &
Process audit ..) followed up and updated in a timely
manner?
● Are the corrective action plans submitted to TRW by
the required dates?

7.3 Are complaints quickly reacted to and ● Contingency plans ● Are contingency plans in place to guarantee
the supply of parts secured? ● Resources and reaction times for sorting actions delivery and quality in case of unplanned concerns?
● Plant modification possibilities, special production ● Do they take into account capacities and reaction
means and tools time for containment and corrective actions?
● Use of subcontracted resources. ● Are appropriate plans in place in case long/ risky
supply chain has to be contained?

Date: 31 Aug 2005 442736514.xls; E7.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 17 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Questionaire

Supplier: 0 Audit Date: 30-Dec-1899

Location: 0 Report #: 0

7.4 Are fault analyses carried out when ● Analysis possibilities (Laboratory, inspection/test ● Does the supplier carry out professional failure and
there are deviations from the quality equipment, personnel) root cause analysis in case of concerns?
requirements and are improvement ● PARETO Analyses of failure characteristics ● Are quality concern & corrective action reports
measures implemented? (internal/external) issued right in time to TRW in case of quality
● Involvement of all affected departments concerns (If applicable does the supplier use the
(internal/external) TRW VIN Concern Tracking System)?
● Use of problem solving methods (e.g. 8D Report) ● Are corrective actions verified for effectivness?
● Correction of sampling deviations ● Are there recurring concerns?
● Revision of the specifications
● Check of effectiveness.

7.5 Is the personnel qualified for each ● Employee Records ● Customer service
task? ● Job Descriptions ● Product inspection and testing
● Organization Charts ● Storage/Transport
● Training Records ● Logistics
● Fault analysis.
● Knowledge of the following, for example, must be
available:
▪ Product/specifications/special customer
requirements
▪ Standards/Legislation
▪ Processing/Application
▪ Evaluation methods (e.g. audit, statistics)
▪ Quality techniques (e.g. 8D Method, Cause/effect
diagram)
▪ Foreign languages (English minimum)

Date: 31 Aug 2005 442736514.xls; E7.0 Process Owner/Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 18 of 20 E. Carpenter / VP Purchasing
Part & Process Audit: Corrective Action Report
Supplier/ Location: 0 Issued by:
Supplier Code: 0 Status:
Components/ part #(s):

Date Review dates: Scheduled Actual Name

Parts & Process audit
<Other>
<Other>
<Other>
<Other>

Status
Audit
Date (open/ Completion
No. Ref Concern/ Problem Action Due date Responsibility date
started overdue
No.
closed)

Date: 31 Aug 2005 442736514.xls; CAR Process Owner / Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 19 of 20 E. Carpenter / VP Purchasing
 Status
Audit
Date (open/ Completion
No. Ref Concern/ Problem Action Due date Responsibility date
started overdue
No.
closed)
Distribution:

Date: 31 Aug 2005 442736514.xls; CAR Process Owner / Department:

Revision: C K. Gillis / Supplier Development
Doc No: D_030_4_02 Approved by:
Page 20 of 20 E. Carpenter / VP Purchasing