PS - Copy of Supplier PSO

Supplier Process Sign-Off Instructions
GENERAL: The Supplier Process Sign-Off (SPSO) is intended to be a "Quality Systems and Manufacturing
Readiness" verification. The SPSO will evaluate both the Documentation and whether the required systems are
Implemented effectively. The SPSO must be initiated prior to the Suppliers part submission to Johnson Controls.
The Advanced Quality Engineer (AQE) will schedule and lead the SPSO using the Supplier Process Sign-off
form.
STEP 1 - SPSO SUPPLIER SELECTION: The Program Manager, with input from the SDT and Materials Manager,
identifies which suppliers on their program will require a Supplier Process Sign-off (SPSO), and whether the
SPSO will be attended/led by JCI or to allow the Supplier to perform the SPSO themselves. The program SPSO
selections should be completed as early as possible in Phase 2.
Note: The Decision whether to schedule a JCI attended/led SPSO or have the Supplier conduct their own is a subjective
one. Program SDTs should consider the risk factor the Supplier or purchased part pose to their program success. Some
factors to consider are:
1.) What is the Suppliers past/present quality performance? e.g., PPM, on-time delivery, etc.
2.) How critical is the Supplier's component to the overall success of the program?
3.) Is the Supplier new to JCI? New to the automotive industry?
4.) Does the component involve a new manufacturing process or technology for the Supplier?
5.) What is the Suppliers rating with JCI Purchasing or Supplier Development?
STEP 2 - SCHEDULE SPSO: The AQE must notify each supplier that they have been selected for an SPSO and
communicate the SPSO and AG's expectations. This includes sending the supplier a blank copy of the SPSO
form, the detailed questions and the Supplier Part Plan.
The Supplier should prepare for the SPSO by reviewing the requirements in the Global Supplier Standards
manual (www.jcimanual.com) and the Detailed Questions on the SPSO form.
NOTE: The Supplier PSO Part Plan is a new requirement, replacing the previous Supplier Material Sign-off process.
a) The Advanced Quality Manager, with assistance from the Materials Manager, should fill out information in the
"Completed by JCI" columns of the Supplier Part Plan prior to sending to the Supplier.
b) The Supplier PSO Part Plan should then be sent to the supplier's Quality Manager at least two weeks prior to
the SPSO review date. The supplier is responsible for completing the remaining information on this form.
STEP 3 - CONDUCT SPSO: The SPSO team (JCI and Supplier representatives) should first review/evaluate all
the Document requirements on the SPSO form and then evaluate whether or not required systems were
effectively Implemented into the plant and/or manufacturing line.
DOCUMENT REVIEW - All documents, forms and supporting records must be evaluated for completeness, content
and overall quality.
IMPLEMENTED REVIEW - The (AG purchased part) manufacturing line will be evaluated to ensure that the required
quality, manufacturing and supporting systems have been implemented and are functioning effectively. Finally, the
SPSO team must verify the manufacturing line Run-at-Rate requirements. The SPSO team must document the total
good parts produced in a unit time and compare it to the Run-at-Rate goal.
STEP 4 - RED / YELLOW / GREEN: The Advanced Quality Engineer must evaluate each item on the SPSO form
against the objective evidence provided. When the SPSO line item requirement has been suitably demonstrated, the
item is marked GREEN. Any requirement that does not meet the satisfaction of the SPSO team will be marked RED
(high risk) or YELLOW (low risk), and the issue is added to the SPSO Action Item list.
NOTE: Any items which do not apply to this supplier shall be marked as "N/A," and the reason why this is not
applicable shall be recorded in the "Comments" section of the corresponding detailed checklist item.
STEP 5 - APPROVE SPSO: The SPSO is approved (signatures on the SPSO form) when all SPSO form items are
GREEN. The SPSO Leader will change a RED or YELLOW to GREEN when the SPSO Issue has been corrected and
verified.
LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Page 1 of 11
(01-October-2007) Confidential and Proprietary
Supplier Process Sign-Off
Program Model Yr./Name: Date of SPSO:
Part/Assembly Name: JCI User Site:
Part #: Part Rev Level:
Supplier Name:
Document Implemented
G/Y/R G/Y/R Requirement

1 Plant Layout & Process Flow Diagram complete
2 Design and Process FMEA complete (as applies)
3 Product Control Plan available
4 Purchased Components Readiness / Sub-supplier Part Submission complete
5 Product Specifications/Drawings/Blueprints available
6 Tooling, Equipment, and Fixtures identified
7 Operators Trained and Instructions available
8 Parts Handling Plan available
9 Parts Packaging/Shipping Specifications available
10 Key Quality Systems demonstrated
11 Containment Plan available
12 Preventive Maintenance plans established
13 Gage & Check Fixture R&R studies completed
14 Production Validation complete (as applies)
15 Line Speed and Capacity verified
16 Materials Readiness demonstrated
Line Speed (Capacity) and Yield

# of Good parts built (A)
# of Total parts built (B)
Total run time, min. (C)
Build Rate, min/pc (=C/A)
Yield, % (=A/B * 100)
Y/N
Onsite revisit required? Date Planned
Approvals
GREEN - Element complete

JCI Quality Engineer
YELLOW - Not complete, but little risk
Supplier Quality Eng.
RED - Element not complete
Page 2 of 11
Supplier Project Mgr.

Page 3 of 11
Supplier PSO - Detailed Questions
Program Model Yr./Name: 0
Supplier Name: 0
Date of SPSO: 30-Dec-99
1. Plant Layout and Process Flow Diagram

STATUS
DOCUMENTATION QUESTIONS (G/Y/R) Comments
1. 1 Is there a dated copy of the current floor plan readily available?
Does the floor plan identify the following:
1. 2 All required assembly, process and inspection stations?
Locations for all raw material, work in process (WIP) and finished product?
1. 3 Are process flowcharts dated and current?
IMPLEMENTATION / PROCESS QUESTIONS
1. 4 Does the actual material and production flow follow the process flowchart?
1. 5 Does each workstation provide adequate lighting and sufficient space to promote effective working conditions?
1. 6 Are inspection point locations effective in preventing shipment of nonconforming products?
1. 7 Is there an identified area for nonconforming material, segregated from the manufacturing area?
1. 8 Is the procedure to re-qualify all reworked/repaired material being followed?
2. Design and Process FMEA

STATUS
DFMEA (If Supplier is Design responsible)
2. 1 Does the DFMEA have the correct Part #, Revision Level, Orig. Date and Rev. Date?
Does the DFMEA include all functional specifications, appearance specifications, SCs and Safety Requirements as
2. 2
defined by Johnson Controls' drawings?
2. 3 Are there RPN calculations for each failure mode and recommended actions for high risk RPN's (>Threshold)?
PFMEA
Does the PFMEA include all Johnson Controls' and internal SCs and Safety Requirements as defined by Johnson
2. 4
Controls' drawings and internal requirements?
2. 5 Are there RPN calculations for each failure mode and recommended actions for high risk RPNs (>Threshold)?
2. 6 Does the PFMEA follow the process flow?
3. Product Control Plan

STATUS
3. 1 Does the Control Plan have the correct Part #, Revision Level, Orig. Date and Rev. Date?
3. 2 Does the control plan follow the process flowchart?
Does the Control Plan include the following: Incoming Inspection, In-process Inspection & Controls, Final Part Audit
3. 3
and Pre-Launch Containment Requirements?
Does the Control Plan include all the Johnson Controls' SCs and Safety Requirements as defined by Johnson
3. 4
Controls' drawings?
3. 5 Are appropriate potential failure modes, as identified in the PFMEA, addressed through the control plan?
Does Control Plan include both gage and test requirements?
3. 6
(including quantity, frequency, and required specifications?)

Page 4 of 11
Supplier Name: 0

3. 7 Are all controls (including SPC), identified on the PFMEA and Control Plan, being used in the production process?
3. 8 Are all controls verified on a periodic basis to ensure desired results?

3. 9 Are all the elements of the control plan being followed?
4. Purchased Components Readiness / Sub-supplier Part Submission Process

STATUS
4. 1 Have you completed a Bill of Material review and have all necessary changes been made?
For each component/supplier with long lead times, do you have an action plan to ensure that adequate material is
4. 2 available to support Johnson Controls' production needs?
Note: unless otherwise specified, Johnson Controls' fab/raw lead time expectations are 2/4 weeks, respectively.
4. 3 Are current specifications available for supplied material?

4. 4 Has an acceptable certification program for incoming material been implemented?
Are there approved Sub-supplier Part Submission Process packages available for ALL Supplier-purchased
4. 5 components? (Note: Supplier part submissions for "Bulk" materials are not required unless requested by any
customer 'downstream'.)
4. 6 Are controls in place to isolate and inspect incoming material? (as determined by projected incoming quality levels)
4. 7 Is there an effective lot traceability system in place?
5. Product Specifications & Drawings

STATUS
5. 1 Is the current revision of the Johnson Controls' specification(s) on hand?
5. 2 Are specifications reflected on drawings correctly?
IMPLEMENTATION / PROCESS QUESTIONS - None
6. Tooling, Equipment & Fixtures Identified

STATUS
6. 1 Is there a list of tooling, equipment and fixtures used for this product?
6. 2 Is all equipment, gauging and tooling the same as will be used in production?
6. 3 Are all tools, equipment and fixtures clearly identified with a number, and with "Property of ____________"?
6. 4 Have customer specific requirements, e.g. branding, been met?

Page 5 of 11
Supplier Name: 0
7. Operator Training & Instructions

STATUS
7. 1 Has a staffing plan been developed to cover launch acceleration and full production requirements?
7. 2 Have all support personnel been identified and has this been communicated to the manufacturing team?
7. 3 Have all off-line job responsibilities been identified and assigned to qualified team members?
7. 4 Have production trainers been identified for each shift?
7. 5 Has a training matrix been set up to track team member training on these procedures?
7. 6 Is a system in place to certify & re-certify operators?
7. 7 Is a system in place to verify operator training on gages, visual aids, and operator instructions?
Are there set-ups, instructions and verification checklists posted for all equipment and operations? Are they being
7. 8
followed?
Are visual aids (including appropriate boundary samples) and operator instructions readily accessible by the
7. 9
operators at each station and being followed?
7. 10 Are visual aids dated, approved & current?
7. 11 Are inspection gages and gage instructions readily available?
7. 12 Are rework and repair procedures in place and being followed?
8. Parts Handling Plan

STATUS
8. 1 Have the handling and storage requirements of material, including delicate components, been reviewed?
8. 2 Are orders in place on components & packaging to support on-time production requirements?
8. 3 Is the storage of material adequate to protect it from environmental factors?
8. 4 Is the storage location for components organized & monitored?
8. 5 Have controls been established to eliminate the potential for an operation to contaminate or mix similar products?
8. 6 Is the access to components limited to authorized personnel?
9. Parts Packaging/Shipping Specifications

STATUS
9. 1 Has adequate protective packaging for finished product been defined?
9. 2 Have records of test shipping containers and trips been documented? (Ex: What was used on PV build?)
9. 3 Does the label meet AIAG and Johnson Controls' requirements?
9. 4 Have you completed and submitted Johnson Controls' Packaging Data Forms (PDF) for all components?
9. 5 Is your system ready to send Advance Ship Notices (ASN) for these parts?

Page 6 of 11
Supplier Name: 0
9. 6 Have you received a copy of the Johnson Controls' routing instructions?
Has the shipping system been established to include:

1) Ship to Location & Dock Code
2) Shipment Frequency & Window
3) Primary Carrier
4) Expedite Carrier (Use NLM's One-Call only!)
9. 7
5) Container Return/Maintenance
6) Saturday <Weekend?> Shipments
7) Freight Ownership & Payment
8) Pre-Production & Production Label Formats
(See www.suppliermanual.com for label formats)

9. 8 Does packaging meet agreed upon standards as reflected on PDF?
9. 9 Does labeling of production packaging meet standards?
10. Key Quality Systems

STATUS
10. 1 Has pilot build data been collected and stored?
10. 2 Is there a returned material authorization (RMA) process in place?
10. 3 Is there a procedure to re-qualify all reworked/repaired material?
10. 4 Are systems in place for continuous data collection to drive process improvement for this part?
Does the problem solving system incorporate the 8-D, or like processes (I.E. Customer specific methods; 7-Step, 5
10. 5
Phase, etc.)?
10. 6 Are all part-specific 8D's which impact this product resolved?
Is the system being followed to ensure the correct revision level is in place for all engineering documents?
10. 7
(Specifications, PFMEA, Control Plans, Setup Sheets, Operator Instructions, Visual Aids)
Are all "Master Good / Master Bad" samples available on line? Are they signed & dated?
10. 8
10. 9 Are trends and out of control situations being noted and corrected?
11. Containment Plan

STATUS
11. 1 Are there procedures in place to protect customer in the event of 'Customer Complaint'?
Do these procedures ensure complete isolation of suspect material, at both customer and supplier locations? At
11. 2
transportation and storage locations?
11. 3 Do Containment procedures drive/trigger problem solving?
11. 4 Is the containment plan adequate to launch a defect-free product?
11. 5 Is there a Plant Contingency Plan written?

Page 7 of 11
Supplier Name: 0
Are the containment audit instructions in place and being followed? Posted at the station/process where the
11. 6 inspection takes place? (Instructions clearly visible. Non-conforming parts should be clearly marked as such and
segregated, until the audit has been completed.)
Are there Labeling and Scanning instructions available? If necessary check for instructions regarding handling of
11. 7
parts prior to containment.
11. 8 Are the Final Part Audit Instructions written and approved?
Is the team tracking the production builds and Containment audit results on the Launch Containment Chart? Are the
11. 9
issues being resolved?
12. Preventive Maintenance Plans

STATUS
12. 1 Has a preventive maintenance system been established for each piece of equipment?
12. 2 Is the preventive maintenance system being followed?
12. 3 Is there an adequate supply of perishable tooling available in house?
Are all "Master Good / Master Bad" samples on the Preventative Maintenance schedule?
12. 4
13. Gage & Check Fixture Evaluation

STATUS
13. 1 Has a gage / test fixture proveout checklist been completed? (if applicable)
13. 2 Have all gages been dimensionally certified?
13. 3 Were gage R&R's performed and acceptable (<10%) on all variable data measuring instruments?
Were gage R&R's performed and acceptable (ref. AIAG "Measurement Systems Analysis" manual) on all attribute
13. 4
measuring instruments?
13. 5 Are procedures in place to calibrate test & measurement equipment on a regular basis?
13. 6 Has a list of untested components been compiled? (if applicable )
13. 7 Are test intermittent and open issues documented? (if applicable)
13. 8 Are identified master good & master bad parts in place for the build?
13. 9 Are all gages and test equipment properly calibrated and traceable to a known standard?
13. 10 Are Engineering Change levels and calibration dates clearly called out on all gages?
13. 11 Do gages and test fixtures properly locate the part (ref. part drawing) and check necessary part features?
13. 12 Are procedures being followed to calibrate test & measuring equipment on a regular basis?
14. Product Validation Complete

STATUS
14. 1 Is Design Validation and Production Validation data present for all items requiring validation?

Page 8 of 11
Supplier Name: 0
14. 2 Has all the validation data been analyzed with acceptable results?
If any items in 14.2 requires "level -up" countermeasures, are the actions, timing and responsibility plans
14. 3 satisfactory? ("level-Up" are parts that are temporarily acceptable for SOP but will require improvements to meet
specification.)
14. 4 Are all specifications and measurement method(s) agreed among Johnson Controls' and the supplier?
Is the validation equipment capable of performing all the tasks required to test product to Johnson Controls' product
14. 5
validation specifications?
15. Line Speed & Capacity Verified

STATUS
15. 1 Has a machine process capability study been done and documented on all pieces of equipment?
15. 2 Are projected ramp-up and peak demands known?
15. 3 Is there a plan in place to compare your capacity against Johnson Controls' releases at least monthly?
15. 4 Has your manufacturing capacity plan been formulated to accommodate schedule changes?
15. 5 Have the top three bottlenecks in the assembly process been identified?
15. 6 Has an action plan been developed to reduce cycle time of the bottlenecks that were identified?
15. 7 Have contingency plans been established to support production for 2 days in the event of equipment breakdown?

15. 8 Is capacity sufficient to meet Johnson Controls' peak production demands?
Do the number of acceptable pieces coming off the end of line (as documented on SPSO Checklist) meet or exceed
15. 9
production requirements?
16. Materials Readiness Demonstrated

STATUS
16. 1 Has the Supplier Part Plan been completed?
16. 2 Is cycle count frequency for components, WIP and finished goods appropriate for this product?
IMPLEMENTATION / PROCESS QUESTIONS - None

Page 9 of 11
Supplier Part Plan
Supplier Name: Program Name:
Supplier Number: Duns #:
Primary Customer Service Contact: Phone #:
Fax #:
Completed by JCI
Completed by Supplier
Quoted Peak Capacity Leadtime of Finished Goods Seeing Supplier Part

Shipment Volume (units per Shifts per Shifts per Estimated Part Levels (Planned Mfg Ship From EDI from this Submission
JCI Part # Part Description JCI PO # Frequency (Annual) month) Day Week Scrap % to JCI days on hand) Location Location JCI site? Target Date
Supplier Assumptions:

Page 10 of 11
SPSO Action Item List
Program Name: (Customer, model yr, name) Program #:
Part Name: Rev. Level:

Part Number: Last rev. date:
Date of Review:
Person Target due Completion

Quest. # Issue Corrective Action Plan
Responsible date date

Page 11 of 11

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Supplier Process Sign-Off Instructions

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Program Model Yr./Name: Date of SPSO:

Part/Assembly Name: JCI User Site:

Part #: Part Rev Level:

G/Y/R G/Y/R Requirement

Line Speed (Capacity) and Yield

GREEN - Element complete

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Date of SPSO: 30-Dec-99

1. Plant Layout and Process Flow Diagram

2. Design and Process FMEA

3. Product Control Plan

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Date of SPSO: 30-Dec-99

IMPLEMENTATION / PROCESS QUESTIONS

3. 8 Are all controls verified on a periodic basis to ensure desired results?

4. Purchased Components Readiness / Sub-supplier Part Submission Process

4. 3 Are current specifications available for supplied material?

4. 7 Is there an effective lot traceability system in place?

5. Product Specifications & Drawings

6. Tooling, Equipment & Fixtures Identified

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Date of SPSO: 30-Dec-99

7. Operator Training & Instructions

8. Parts Handling Plan

8. 6 Is the access to components limited to authorized personnel?

9. Parts Packaging/Shipping Specifications

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Date of SPSO: 30-Dec-99

9. 6 Have you received a copy of the Johnson Controls' routing instructions?

Has the shipping system been established to include:

IMPLEMENTATION / PROCESS QUESTIONS

10. Key Quality Systems

11. Containment Plan

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Date of SPSO: 30-Dec-99

12. Preventive Maintenance Plans

13. Gage & Check Fixture Evaluation

14. Product Validation Complete

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Date of SPSO: 30-Dec-99

15. Line Speed & Capacity Verified

IMPLEMENTATION / PROCESS QUESTIONS

16. Materials Readiness Demonstrated

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Quoted Peak Capacity Leadtime of Finished Goods Seeing Supplier Part

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

Part Name: Rev. Level:

Person Target due Completion

LT-PLUS-FR-41-E / Rev 07 Johnson Controls, Inc.

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