Manufacturing Requirement for Supplier

MRS
MRS: Manufacturing Requirement for Suppliers
Contents

1 INTRODUCTION

2 EVALUATION Process

3 EVALUATION Form
& SCORING Matrix

4 REQUIREMENT
OVERVIEW
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1 INTRODUCTION

3
 NEW SUPPLIER AUDIT: Manufacturing Requirement for Suppliers
Introduction
• Structure based on ex-QIP

• Supplier audit referential is a ‘pass-through’ multi purpose audit system

• New acronyms:
- QIP ➔ Manufacturing Requirements for Suppliers (MRS)
- NSA/SEA ➔ New Supplier Assessment (NSA)
- PCPA/PA ➔ Progressive Process Qualification (PPQ)
- QSB ➔ Mass Production Assessment (MPA)

• Key elements, requirements ➔ only minor changes

• Criteria and “look for” were reviewed

• All SQE‘s qualified ex-QIP keep their qualification

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 NEW SUPPLIER AUDIT: Manufacturing Requirement for Suppliers
• Objective of the workstream:
- Define the Stellantis supplier audit referential “best of both companies”

• Team workshop:
- Start in March 2022
- All regions
- 60 participants in 15 subgroups
Validated by SQD DIR and direct reports
world-wide (Date of meeting 12/10/22)
• Result of workshop:
- Complete Stellantis
• Audit referential defined and available Doc-Info: 01598_16_04265
• Training material

Selection
Phase Indus. Phase Mass production Phase

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 MRS: Manufacturing Requirement for Suppliers
NSA: New Supplier Assessment (Ex NSA/SEA)

• Purpose:
- Evaluate the manufacturing maturity of a potential new supplier
- Evaluate at the beginning of a program, operational effectiveness of the launch organization on supplier site

• Case of use:
- New supplier or new supplier site.
- Validity limited to 12 months.

• Operational Requirements:
- Performed by service provider (TRIGO; SNECI; BV; ABP; LUMINOUS)
- On RFQ for safety part audit done by SQE
- Maximum duration of the evaluation on site: 1,5 ➔ 2 days
- Self-assessment by supplier before evaluation

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 MRS: Manufacturing Requirement for Suppliers
PPQ: Progressive Process Qualification (Ex PA/PCPA)

• Purpose:
- During Project phase:
- to estimate progress and to obtain a status by phase
- to anticipate the risks & prepare the next phase
- at the end of a project, confirm the qualification status of the manufacturing process

• Case of use:
- The PPQ is a mandatory APQP deliverable (from gate 2 to gate 5), to confirm the status of the
manufacturing process

• Operational Requirements:
- Perform by SQE or Supplier (Self-assessment under SQE approval)
- Duration of the evaluation on site: 1 day from gate 2
- Self-assessment by supplier before evaluation by the SQE
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 MRS: Manufacturing Requirement for Suppliers
PPQ: Progressive Process Qualification (Ex PA/PCPA) Auros or PLM?

APQP grid in AUROS APQP grid in PLM

PPQ template PPQ result

for the gate

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 MRS: Manufacturing Requirement for Suppliers
PPQ: Progressive Process Qualification (Ex PA/PCPA)

➢ How to use progressive PPQ assessment:

During Project phase:

to estimate progress and to obtain a status by phase
to anticipate the risks & prepare the next phase

Use the scoring of PPQ criteria (OK/NOK) to:

1- Rate the PPQ in the APQP grid

• for the ongoing milestone
• ensure action plan for all concerned NOK

2- Rate the other APQP grid items (Control plan, PFMEA, Capability reports, AQR……..) :
➢I f PPQ result is low or, critical criteria linked to APQP deliverables are NOK => review APQP rating (ensure consistency)

3- Prepare the next phase :

➢ identify risks for the next phase (action plan for all NOK PPQ criteria to reach 100% for the next phase)

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 MRS: Manufacturing Requirement for Suppliers
PPQ: Progressive Process Qualification (Ex PA/PCPA)
PFMEA description: Assessment (Specific case)
PFMEA check list, included in PFMEA synthesis (APQP deliverable) ref 01272_06_00043

Assessment during development:

→ Similar to look for section
RR11
→ Be consistent between PFMEA APQP rating and RR1
rating in PPQ

RR12

RR13

RR14

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 MRS: Manufacturing Requirement for Suppliers

Indus. Phase

• 1 Day (Level 1) ➔Focus customer protection • 2 Day (Level 2) ➔ Extended version ➔ full audit
and shop floor (Gemba) ➔ partial audit referential Escalation, exit criteria…..
referential

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 MRS: Manufacturing Requirement for Suppliers
MPA: Mass Production Assessment (Ex QSB+)

• Purpose:
- Evaluate the overall robustness of processes on site
- Drive the continuous improvement (identification of weak points & opportunities for improvement)

• Case of use:
• 1 Day (Level 1) ➔Focus customer protection and shop floor (Gemba) ➔ partial audit referential
Frequency depending on supplier criticality (Low/Medium/High) To be determine by STLA
technical lead

- High Risk 2 x year​

- Medium risk every year​
- Low risk every 3 years

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 MRS: Manufacturing Requirement for Suppliers
MPA: Mass Production Assessment (Ex QSB+)
• Criteria of decision (Risk assessment criteria)

• Excel table

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 MRS: Manufacturing Requirement for Suppliers
MPA: Mass Production Assessment (Ex QSB+)
• Key elements selected

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 MRS: Manufacturing Requirement for Suppliers
MPA: Mass Production Assessment (Ex QSB+)

• 2 Days ➔ Extended version ➔ full audit referential

Escalation, exist criteria, yard hold..

• Operational Requirements:
- Perform by SQE
- Maximum duration of the evaluation on site : 1 day (Level 1) or 2 days (level 2)
- Self-assessment done by supplier himself

• Operational qualifications:
- No need for re-qualification for the L2 and L3 previously qualified
- New qualification process to be used beginning on Q1 2023

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2 EVALUATION
PROCESS

16
MRS: Manufacturing Requirement for Suppliers
MRS: Preparation of (NSA/PPQ/MPA)

• This meeting is the first step to prepare the evaluation.

• It should be planned at least 3 weeks before the audit, but note that in case of emergency it can be performed
only few days before (at discretion of the auditor).

• Intent
• Validate the key milestones (intermediate meeting, date of communication of the self-evaluation, date of
audit).
• Present MRS tool (NSA/PPQ/MPA) (rules of scoring, key element, action plan management …..)
• Transmit the key documentation (audit sheet, training material, generic agenda).
• Validate key points of the agenda :
• Timing of shift change and « FR meeting ».
• Distance between different workshop, warehouse …
• Support of Corporate functions (Eg: Project Management, Contingency Plan, Warranty…)

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 MRS: Manufacturing Requirement for Suppliers
MRS: Preparation of (NSA/PPQ/MPA)

• Supplier Self-Assessment is a key step in the MRS tool (NSA/PPQ/MPA) evaluation process

• Self-assessment increases effectiveness during on-site audit: no loss of time both for supplier & customer

• Intent
• Supplier awareness of requirements
• Gap analysis between requirements and supplier current system
• Assure supplier readiness before customer on-site assessment

• Hint
• To obtain best results, an honest self assessment is recommended
• Red result has no negative affect but help to identify weak points
• Comments are required: explanations with supporting evidence are as important as the scoring

• Note: Self-assessment can be avoided in case of emergency situation (auditor decision).

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MRS: Manufacturing Requirement for Suppliers – Good practices
MRS: audit grid structure (NSA/PPQ/MPA)
Example
Criteria Criteria
Quotation SD Site
#Criteria Criteria requirement Look For Quotation (OK / Quotation Quotation (OK Comment Supplier Comment STLA
Suggestion Re-quotation
NOK) / NOK)

Where : Before the audit and during the audit in meeting

roomWith : Quality ManagerCheck before the audit (if
possible) that the certificate is valid :- - Not suspended, -
Without any non-conformity (all actions plan are closed)
The plant is IATF 16949 certified.If not certified or
.Check, during the audit, the full report of last external
suspended, an action plan is implemented,
CMP11
managed by the Plant Manager and supported by
audit.For a new or greenfield supplier :- - If the OK
certification audit is scheduled at least before SOP. - If not
the corporate.
possible, the "letter of conformance" is planned to be
granted before SOP. - Action plan is in place- In
compliance with Check list "greenfield" ref
01598_15_06479 ITEM 3.5 "plant certification" :
Where : Before the audit and during the audit in meeting
roomWith : Quality Manager and/or Logistic
ManagerCheck before the audit if the self evaluation is
To be
Yearly MMOGLE self evaluation is done and
CMP12
shared with PSA. All actions are managed.
present and yearly updated in PSA IT systems.Check if the OK 3 comp
result of this evaluation is in line with supplier KPI (issue,
service rate).In NSA : check if MMOGLE self evaluation is leted
done, managed and communicated to other customers.
Where : Before the audit and during the audit in meeting
roomWith : Quality Manager and/or Logistic
ManagerCheck if :-Main documents are known, supplier
has subscribed in Doc Info for those documents (E.g. :
SQM, MLP, GP5+, GP12...)Supplier contact details are
CMP13 OEM's documentation is known by the supplier. properly identified in Amadeus (Quality & Logistics) & OK
MKA systemAsk supplier to demonstrate how to access
the B2B portalSQM&MLP : Verify that supplier knows the
last versionSupplier is aware of key processes (E.g. : GP5+
when to require 5 why?, MLP : Where is the service rate
measured?

Each criteria need to be assessed in Supporting evidence in line with each

order to determinate automatically the criteria quotation (OK/NOK) are to be
quotation of the requirement. entered in the dedicated column.

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MRS: Manufacturing Requirement for Suppliers – Good practices
• The summary sheet of the MRS tool (NSA/PPQ/MPA) is presented during the closing meeting of the audit in order to prepare the action
plan. It must be sent to the supplier at least 2 days after the audit (mandatory step).
• The final report must be sent to the supplier at least 2 weeks after the audit.
• Supplier must provide action plan to the auditor for approval within 4 weeks of receiving final audit report.
• This action plan will be validated by the auditor.
• The robustness of actions must be followed by the SQE.
Property of STELLANTIS– Restricted document

NSA - New Supplier Assessment

Supplier Name Pass Automotive SA de CV Scope of Audit Complete Supplier Plant Mfg. Maturity Evaluation

Supplier Location Libramiento León - Querétaro km 4.6 Col. Las Malvas Irapuato, Guanajuato CP 36546
Audit Date 8-9 September 2022

Supplier DUNS / COFOR 812718332 Auditor Name Dennis Gauthier

SAFETY COMPONENTS Result <70% 70% <= Result < 90% Result >= 90%

Self Assessment Scoring Customer Audit Scoring

Comment
Key Elements Potential Total % Status Potential Total % Status

+ TS -16949 Certified, MMOGLE by Ford 100%

Best practices and main deviations are commented

1 Corporate Management Plant CMP 6 6 100% G 9 6 67% Y - Need risk assessment for hail damage to maintain production
- No standard to determine the number of parts required for incoming inspection.
+ Plant APQP process starts upon receipt of SOP and SOBA and weekly meetings are held to
track

for each key element (with context)

alignment of key milestones to customer
2 Corporate Management Group CMG 9 9 100% G 9 4 44% Y - Control completion due date not filled in
- Customer project timing not aligned with plant project timing
- New skills for new project not identified
- Missing tracking informatiion in FR Board (timng)
- Missing information in each significant zone, i.e., scrap, alarm limit, etc.
3 Fast Response FR 9 9 100% G 9 3 33% Y - Escalation process isn't reviewed during FR meeting
- Problem solving 5Y process not used systematically
- Recurring Top Problem Plant issue is not reviewed in FR Meeting
- Control plan inspection & tests not performed at the correct frequency (5 piece layout
requirement,
but only 1 piece layed out completed)
4 Parts and Process Control PPC 9 9 100% G 9 4 44% Y
- In case of no non-conformity (all of the lights should be green, but leak tester is showing all
lights
green except for just one white). There is no reaction plan.
- Start of process.. Standard work instruction requirements do not align with what is shown in
picture
5 Start of Production & Error Proofing Management
SP&EP 9 9 100% G 9 3 33% Y
- No reactivity regarding function of the green light
- Error proofing at the leak test not effectively managed. This was not escalated in FR meeting
- Check list with timing is not identified in the process
6 Warranty Issues Management WIM 3 3 100% G 3 1 33% Y - Warranty Coordinator is not identified

Final result appears after implementation of the

+ Ergonomic program is well executed…Risks identified and actions taken to reduce high risk
items..
7 Standardized Work SW 9 9 100% G 9 4 44% Y - Security training…Audit team was not informed or provided security training before entering the
plant floor
- No 5S activities conducted

8 Control of Non-Conforming Product CNC 6 6 100% G 6 4 67% Y

- Visual
+ No documented
managementreaction plan
of part for gauges
labeling that failof
and location Gage R&R capabiilty
non-conforming study
material
- Operator at Ford leak Test did not give a proper response for reactivity to rejected assembly
- No formalized documented process for the containment of non-conformring material
+ PFMEA's are available for all of the operation
scoring in the audit questionnary
- Contamination is not identified in PFMEA
- No evidence that the team conducted a review to reduce high RPM
9 Risk Reduction RR 9 9 100% G 9 4 44% Y
- No evidence of recommended actions documented in PFMEA's with Responsibilies and due date
- After issue PFMEA was updated with action, but the scoring didn't change
- Reverse PFMEA's are not conducted
10 Managing Change MC 3 3 100% G 3 3 100% G + Managing change is managed properly (no gap to requirements)

+ Maintenance process is implemented

+ All of the maintenance activity is recorded
11 Maintenance MAI 6 6 100% G 6 5 83% Y
+ List of critical spare parts is managed properly (no gap to requirements)
- Preventative maintenace doesn't take into acount risk (bottle kneck, Supply Chain, etc.)
+ Supply of the production line is properly managed ( FIFO, Replenishment)

General comments focused on the action plan.

12 Manufacturing & Material Flow Management
MMFM 6 6 100% G 6 5 83% Y - Master production schedule does not take into account OEE in production planning
+ Incoming inspection…process to follow delivery is formalized and aministrative control is in place
13 Inbound Logistics ILG 9 9 100% G 9 8 89% Y + EDI is properly managed
- No evidence that sample size is modified based on the material performance
+ Final product (packaging) is managed properly
14 Outbound Logistics OLG 6 6 100% G 6 5 83% Y - Standardized Work Instruction (SWI) doesn't exist for the cleaning of empty returnable containers

- Generic Layered Process Audit is not aligned with Stellantis request (maintenance and SL is not
part
15 Layered Process Audit & Skills Management
LPASK 6 6 100% G 9 4 44% Y of audit)
- Error Proofing is missing in the checklist.
- Operator qualification.. No focus regarding key characteristic (reactivity)

16 Tier N management EXTRA 8 8 100% G 10 9 90% G

If any of Requirement is scored by 0 overall result goes to Red
Audit Summary Scoring limits depend to safety component specification.
Total Score
113 113 100% G 121 72 60% R

Green - Recommended
Yellow - Recommended with action plan
Audit Result Recommended Not Recommended Red - Not Recommended
Not Relevant : Less than 90% of requirement rated - New review needed

117 criteria requirements evaluated

General Comment 68 criteria requirements found OK
49 criteria requirements need action plan implemented
No new evaluation will be performed with Stellantis before 6 months if Pass wants to be considered for Stellantis business

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MRS – Certification
MPA – 2 Distinct processes

Preventive action Structural maturity

“Monitoring plan” assessment complementary
to IATF

Risk assessment criteria MPA Certification process

(Hight; Medium; Low) (Impact Bidlist)

21
MRS – Certification

• Certification is granted for a 3 years period (Coherence with low-risk status)

• All suppliers may be certified whatever their risk evaluation is (High, medium, low)

• Supplier certification is done during MPA -1Day

• Waived status possible among the low-risk suppliers for those with very low risk (by hand of SQE)

• If the supplier doesn’t reach the certification within 6 months, Stellantis can impose service provider support at
supplier expense.

Self-assessment will be ask to the supplier

Certification will be prononced by SQE after MPA L1
Manufacturing location will be subject to the bidlist penalty
22
MRS – Certification
– Current supplier (Known in bidlist)
Result = Pass

MPA status Certified Evaluation of Annual

Complete
Action Plan
Action Plan by Supplier self-
BIDLIST 0 SQE assessment

Result = Conditional Pass*

MPA Conditional
MPA status Pass Certified
BIDLIST 0
Certification Max: 6 months
Audit Evaluation of
Complete
Action Plan by
Action Plan
Result = Fail** SQE on site

MPA status Not

certified
BIDLIST ?
Training if needed by
service provider

23
MRS – Certification
– New supplier

PPQ Result = Final result green

MPA
Self assessment
PPQ Supplier self- MPA
verification by SQE
assessment
Certification
Audit
Training if needed by (Previous page)
service provider

• MPA 1Day must be perform by SQE within 6 months after PPAP

• The self assessment verification means that all criteria are scored with a robust comment

24
3 EVALUATION Form
& SCORING Matrix

25
 MRS: Manufacturing Requirement for Suppliers
Struture of evaluation worksheet

MRS
Number requirement (1) 4
Structure strictly
Number of criteria in each requirement (2) 4
applied for each
Number of criteria in effectiveness requirement (3) 3 Key element
Example : LPA
Layered Process Audit & Skills Management
LPASK11
Generic Layered Process Audit LPASK12

2
LPASK1
(LPA) LPASK13

1
LPASK14
LPASK 21
LPA records and action plans LPASK 22
LPASK 2
tracking LPASK 23
LPASK 24
LPASK 31
LPASK 32
LPASK3 Operator qualification process

3
LPASK 33
LPASK 34
LPASKE1
LPASKE
effectiveness - LPA & Skill
management
LPASKE2
LPASKE3
LPA = 15 Criteria

BENEFIT=> better balance between requirements & criteria

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MRS – Manufacturing Requirement For Suppliers
Evaluation Worksheets – Creation of the empty form

• Evaluation form is an Excel Worksheet available in B2B portal

• To Create an empty form, click on “Header” sheet https://docinfogroupe.stellantis.com/ead/doc/ref.01598_16_04265/v.vc/pj

① Need to click the button in order to generate the desired assessment work sheet.
② Need to click to OK button to create the new form (No intervention number required)

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MRS – Manufacturing Requirement For Suppliers

• Header
Input of basic information (Supplier Identification, date,….).

Summary
Result of audit/self assessment calculated automatically.
• Audit
Questionnaire list.

• Action plan (generated after clicking on “action plan button” on header sheet).
Supplier action plan to close gaps identified during customer audit.

• Instruction and Training

Description of usage of MRS questionnaire.
Link to material training in Stellantis B2B portal.

• Action plan Instruction

Description of usage of action plan sheet.

• NSA/PPQ/MPA instruction
Special instructions for NSA evaluation.
• Glossary
Complete list of abbreviations used in audit list.
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MRS – Manufacturing Requirement For Suppliers

• Item
Key element abbreviation (e.g. FR - Fast Response).

• Requirement
General definition/summary of the intent of Key element

• Extra scoring
Identification of the criteria with double impact. The quotation of these criteria will impact another one key
element called “EXTRA” on the summary sheet.

• Criteria
Abbreviation for specific criteria identification (e.g. FR21 for the first criteria of requirement FR2).

• Criteria Requirement
Detailed deployment of 'Requirement' in bullet point format.
Used for collecting evidence and setting up scoring.

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MRS – Manufacturing Requirement For Suppliers

• Look For
Auditor hints and techniques for how and what is needed to be checked besides 'Criteria Requirement’.

• Supplier
Criteria Quotation (OK / NOK):
Mandatory self assessment, done by the supplier, as defined in « instruction and training » sheet.
Quotation :
Automatic scoring based on the rules of criteria quotation defined in « instruction and training » sheet.

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MRS – Manufacturing Requirement For Suppliers

• Stellantis Current audit :

Criteria quotation (OK / NOK):
Quotation filled by Customer/ Service Provider (same usage as defined for supplier quotation).
Quotation Suggestion :
Automatic scoring based on the rules of criteria quotation defined in « instruction and training » sheet
SQE and service provider Site Re-Score :
In some cases (must be justified), the auditor can decrease / increase the automatic quotation (more
details page 17).
➔ e.g. The criteria is not completely implemented in the plant but several examples were checked during
the audit. To be checked during next review.

• Comment
Notes for evidences and non-conformances are mandatory.
For the self-assessment, supplier must provide comments for each criteria
Deviations need to be described in a way that action plans can be clearly defined.
Customer Re-score need to be justified in order to explain the real status of the situation.

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MRS – Manufacturing Requirement For Suppliers

- Requirement - Criteria’s identification. - Auditor hints and techniques how and

identification. - Detailed deployment of 'Requirement' in bullet what need to be checked besides
- General Definition, points. Supplier has to operate a system to meet 'Criteria of Requirement’.
summary of the intent listed expectations.
of requirement. - Extra scoring status (for tier n requirements).

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MRS – Manufacturing Requirement For Suppliers
• Bold and unbold

• Basic criteria (Bold type) ==> Basic key requirements ( must have)
• Additional criteria (unbold type) ===> adittionnal requirements (recommended best practice)

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MRS – Manufacturing Requirement For Suppliers

• Score implementation of each requirement is based on the evidences collected during the
on-site audit.
• These evidences will provide a status for each criteria in order to automatically score the
requirement.
• Exception: the customer can increase / decrease this score :
• Increase ➔ Small improvement needed and customer agreement.
• Decrease ➔ Strong action plan needed and/or no customer agreement.

• Some equivalency can be accepted if meets the intent of the criteria defined in the “look
for”.

Example

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MRS – Manufacturing Requirement For Suppliers

Each Criteria is scored according to the following scoring matrix:

Status Scoring for implementation of requirement

OK Compliant (standardized and fully implemented)

NOK Not compliant (not standardized and / or not fully implemented)

NR Criteria not evaluated (to be evaluated during next Stellantis review)

NA Criteria not applicable (should be justified)

Only for NSA in case of critical situation identified (no resource or no decision to implement the
ROAD BLOCK
action plan)

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MRS – Manufacturing Requirement For Suppliers

Each Requirement is scored automatically from 0 to 3 according to the following scoring matrix:

Pts Basic Criteria Status Additional Criteria Status

Audit Goes
RED 0 Number of "Road Block" ≥1

1 Number of "OK" < 50% of Total

2 Number of "OK" ≥ 50% of Total

No impact on requirement scoring
All Basics 3 Number of "OK" = 100% of Total
implemented
NR Number of "NR“ ≥ 1

NA Number of "NA“ > 50%

No impact of additional criteria in NSA scoring. But they can be evaluated in order to prepare
next PCPA & QSB+ audits.

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MRS – Manufacturing Requirement For Suppliers
Number of "OK" = 100% of Total Number of "OK" >= 50% of Total

Number of "OK" > 0

Number of "OK Bold" = 100% of Total

Number of "OK" >= 50% of Total (No impact from additional) criteria Number of "OK"= 0

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MRS – Manufacturing Requirement For Suppliers
15 Key Elements (and 1 “EXTRA”)
MRS

Key Elements MRS MPA L1 MPA L2 PPQ NSA

1 Coorporate Management Plant CMP 4 0 4 2 3
2 Coorporate Management Groupe CMG 4 0 4 3 3
3 Fast Response FR 4 3 4 3 3
4 Parts and process control PPC 4 3 4 3 3
5 Start of production& Error proofing managment SP&EP 4 3 4 3 3
6 Warranty Issus Management WIM 4 0 4 0 1
7 Standardized Work SW 4 3 4 2 3
8 Control of Nonconforming Product CNC 4 3 4 2 3
9 Risk Reduction RR 4 3 4 2 3
10 Managing change MC 4 0 4 1 1
11 Maintenance MAI 4 0 4 3 2
Manufacturing & Material Flow Management
12 MMFM 4 0 4 2 2
13 Inbound Logistc ILG 4 0 4 1 3
14 Outbound Logistc OLG 4 0 4 2 3
15 Layered Process Audit & Skills Management LPASK 4 3 4 1 3
16 Tier N management Extra 4 0 4 4 4
TOTAL of requirement 64 21 64 34 43

MRS MPA L1 MPA L2 PPQ NSA

Total of requirement 64 21 64 34 43
Total of criteria 225 84 225 85 117

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MRS – Manufacturing Requirement For Suppliers
Focus on the management of « Tier n » : additonnal strategy impact

4 « MRS » requirements flagged as “Tier n”

These have double impact in audit scoring: CMP1,3 ; MC1, ILG22

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4 REQUIREMENT
OVERVIEW

40
MRS – Manufacturing Requirement For Suppliers

#1: Corporate Management Plant (CMP)

Level of certification :
• Status of IATF16949 certification & MMOGLE self-evaluation.
• Stellantis (Or other customer for NSA) IT system (B2B) knowledge of documentation (e.g., QRS, MLP).

General Risks management to guarantee manufacturing activity :

• Natural risks (floods, fire,…) & “Supply chain” risks (loss of energy, part supply…).
• By-pass processes and back-up solution (e.g., safety stock)

Tier n supplier management Product / Process qualification :

• Evaluation and selection of supplier.
• Escalation process (approved supplier list monitoring) & Audit policy.
• Incoming inspection.

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#2: Corporate Management Groupe

Project Management :
• Plant involvement during project.
• Project milestones & management of deviation.
• Identification of new skills.

Product / Process qualification :

• Manufacturing process development, and progressive PPQ.
• Mass production tooling (Machine and layout validation)

Identification of the Key Process Characteristics

• Customer approved drawing.
• Key characteristics are deployed into documents.
• Customer specific requirements are deployed to tier n suppliers.

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#3: Fast Response (FR)

Fast Response meeting :

• Daily leadership meeting.
• Fast response Board to track internal & external issues.
• Visual management on the line.

Escalation process :
• Internal & external communication in case of issue.
• Communication between shifts (e.g., Shift book management).

Standardized problem-solving methodology :

• Used for all types of concerns.
• Standard tools defined for finding the root cause to corrective action (e.g., 8D)
• Management of lessons learned.

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#4: Part & Process Control (PPC)

Control plan implementation

• Control plan checks are performed at the correct frequency and sample size.
• All control records are documented and managed in case of deviation.

Capability of the control devices

• Capability of measuring equipment.
• Capability review of processes with high risk.
• Process stability is monitored.

Reinforced controls (safe launch)

• Strategy to implement reinforced controls is defined.
• Reinforced controls are standardized.
• Reinforced control is managed and documented in fast response board meeting.

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#5: Start of production & Error proofing

Start of production :
• Set up process.
• Set up record & reactivity.
• Traceability.

Error proofing management

• Master list of error proofing devices.
• Error proofing management.

L1 Maintenance management :
• Definition of L1 maintenance operations.
• Planning & follow-up (records).
• Operator suggestions & lessons learned management.

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#6: Warranty Issus Management (QEC Management)

Organization and process and treatment :

• Process of WIM is formalized.
• Coordinator is identified and his/her mission formalized.
• Suspect parts are managed.

Pre-analyses phase :
• Engineering and quality resources are identified and available.
• Immediate containment is applied
• Pre-analysis phases are link to the claims gravity.

Customer protection:
• Reinforce the control plan following the PFMEA review.
• Visual management is in place displaying
• The supplier has identified and contact the OEM (including spare parts management.

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#7: Standardized Work (SW)

Workplace organization & ergonomics :

• Safety rules & safety training.
• Safety standard applied for each workplace.
• Organization of the workplace (e.g., 5S, FIFO, visual management).

Working instructions (production process operations & logistics) :

• Standards.
• SWI are developed by cross-functional team and managed
• SWI shall contain at minimum :
- Work elements including quality controls and their sequence
- Operator movement with sketch of workflow

Capability of the control devices :

• All the gages are periodically calibrated and recorded according to procedures.
• The capability of the measurement means is periodically checked according to procedures.
• Reaction plan for each deviation/non-conformity or equipment exceeding calibration due date.

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#8: Control of Non-conforming Product (CNC)

Identification mode of the non-conforming or suspect material

• Visual management and marking parts.
• Segregated part are managed.

Containment process
• The containment operation stock and pipeline.
• Containment worksheet exist and applied
• The certified OK lot identified and communicated to the customer.

Rework or re used operation

• Any rework/repair/re use must be included in the process flow, PFMEA, SW…
• Re-introduction of reworked parts
• Each reworked part are traceable

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#9: Risk Reduction (RR)
PFMEA Scope :
• Generic PFMEA is updated for part specific attributes.
• Content of PFMEA fields and scoring are defined properly in accordance with customer
guideline.
• PFMEA covering all the processes (e.g., incoming material, rework operation, safe launch
plan).
• All failure modes are considered.

Management of the highest risk items :

• Identification & analysis.
• Action plans follow-up and rescoring.

Reactive and Proactive review :

• Periodical reviews :
- Update after internal or external issues.
- PFMEA review based on KPI.
• Reverse PFMEA :
- Real and effective risks verification at the workstation.
- Findings considered for process improvement.
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#10: Managing Changes (MC)
All types of changes (Product & process / planned & unexpected)
• Management of changes (Product, Process, tier n and IT Systems) are defined and applied
• A change form is utilized to document all changes and controlled through a Document Control
Process

Risk Management of Changes

• For any product/process/source change, a feasibility analysis is carried out.
• A risk analysis of changes is performed with a methodology.
• Break point is defined when change becomes irreversible

Production & Traceability

• A standardized communication procedure and form is in place in order to control and monitor
• Traceability of the parts delivered under deviation is guaranteed. Manufacturing batches are
identified.

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#11: Maintenance (MAI)
Maintenance organization & activities (planning & tracking) :

• Available resources & facilities.

• Communication with manufacturing department.
• Preventive maintenance master planning / Corrective maintenance activities.
• Working standards, technical documentation.
• Maintenance records (equipment diary…).

Spare parts management :

• Critical spare parts list & standardization Policy.

• Stock management & storage conditions

Maintenance of Customer Specific Tool :

• List of Customer Specific Tool (CST) by Customer is established and managed.
• The storage of Customer Specific Tool is organized and managed
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#12: Manufacturing & Material Flow Management (MMFM)

Manufacturing scheduling :
• Master production schedule (Stock; Packaging; resource management…).
• Daily manufacturing program.
• Treatment of deviation between forecast and current production.

Management of constraint operation:

• Process flow is identified.
• FIFO and correct part is managed.
• Escalation rules for replenishment are clear at workstation.

Supply of workstations :
• Process flow is identified.
• FIFO and correct part is managed.
• Escalation rules for replenishment are clear at workstation.
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#13: Inbound Logistic (ILG)
Supply process :
• A process to follow deliveries is formalized and applied.
• A Control Plan is established for quality checks on incoming material.

EDI & logistic Electronic Protocol :

• Communication is established.
• Protocol logistic (Rules of handling between supplier & OEM’s).
• Back up solution.

Handling and storage conditions of product :

• Standards for the organization of storage are clearly defined and applied.
• FIFO is respected in storage.
• Visual management is in place.

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#14: Outbound Logistic (OLG)

Shipping process (Outgoing) :

• Shipping process is formalized and applied.
• Key milestones are set in order to alert customer
• Loading “Bogus truck” (Fake truck in staging area).

Final product packaging :

• Flow of full / empty packaging.
• IT system is managed (e.g., Packman, Gefbox, CHEP ).

Just In Time (JIT) & sequenced flows :

• Implementation of failure modes in PFMEA & definition of back up solution.
• Strict compliance with customer sequences.

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#15: Layered Process Audit & Skills Management (LPASK)
Generic layered process audit :
• Written procedure which contains the rules of LPA.
• Check sheet definition.
• Schedule implemented and followed.

LPA record and action plan managing :

• LPA performed by operational & top management.
• Result of LPA is recorded and documented.
• Countermeasure is managed with corrective action plan.

Employee Qualification / Flexibility Chart :

• Qualification process & follow up of qualification status.
• Training refreshment.
• Calibration process / standardized work for visual inspection.

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End of the presentation

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History version

Date Comment
08/02/2023 Creation MPA
19/04/2023 Add Slide certification
13/12/2023 Supplier certification Q1 2023
remove

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