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Quality Standards Department
Ford Automotive Operations
Q&PL HQ - Building A
Fairlane Office Park
Dearborn, MI 48121
QSA-E 2
Ford Automotive Operations
Table of Contents
Introduction 4
Appendix A - Glossary 35
Appendix B - Reference Publications 37
Record of Changes and Amendments 38
QSA-E 3 January, 1999
Ford Automotive Operations
Introduction
This document is Ford Automotive Operations’ Quality System Assessment for Engineering
Organizations (QSA-E).
Ford Automotive Operations created the QSA-E to accomplish the following objectives:
Provide a method for assessing the Quality system and technical capabilities of the
engineering locations of potential suppliers prior to sourcing design responsibility(second
party).
Serve as a basis for scoring and rating the technical capability of the product development
organization of suppliers with design responsibility.
SCOPE:
The scope of this assessment is intended to apply at the organization level, encompassing all of a
supplier's product development activities and supporting staff level manufacturing engineering
activities. Certain elements or criteria of the QSA-E may not apply to a given organization, and may
therefore be designated as "NA" (not applicable). If in doubt regarding applicability, contact the Ford
decision maker.
The QSA-E technical capability criteria is supplemental to QS-9000 Quality System Requirements.
Product development locations must be in compliance with QS-9000 including element 4.4: design
Control.
SCORING GUIDELINES:
Supplier scoring or rating is outside the scope of this document. The scoring guidelines found in the
Q1 Award Process and Requirements Manual (10 point scale for each question) may be used to
establish a variable score as a means of internally tracking and reporting the engineering organization's
status of compliance to QSA-E. Scoring is not required for the FSS self-development assessment
process.
QSA-E 4 January, 1999
Ford Automotive Operations
Technical Capability Criteria
QSA-E
QSA-E 5 January, 1999
Ford Automotive Operations
Technical Capability
A. Ultimate Customer
1. Does the organization have a documented system for obtaining
customer feedback data on products over the life cycle of the
product and communicating it throughout the organization?
4. Does the plan include proactive contact with the customer, in order
to prevent future concerns and to understand likely future
requirements? Are visitations scheduled and carried out to plan? Is
the need for additional contact quickly identified and implemented?
QSA-E 6 January, 1999
Ford Automotive Operations
Technical Capability
B. DFMEAs
2 Are DFMEAs expectations met? (i.e. FAO APQP Status Reporting
Guideline, Appendix B - Focus Element Checklist)
6. Has the team completed a risk assessment per section 4.4 of the
FAO APQP Status Reporting Guideline?
9. Does the supplier meet the expectations for the Design Verification
Plan? (Defined in the FAO APQP Status Reporting Guideline,
Appendix B - Focus Element Checklist)
QSA-E 7 January, 1999
Ford Automotive Operations
Technical Capability
E. CONTROL PLANS
13. Are expectations for control plans for Prototype, Pre-Launch and
Production met? (i.e. FAO APQP Status Reporting Guideline,
Appendix B - Focus Element Checklist)
14. Do all high risk failure modes identified on the FMEAs have
prevention methods designed into the respective processes?
QSA-E 8 January, 1999
Ford Automotive Operations
Technical Capability
SUMMARY QUESTIONS:
18. Does a review of all 23 Key APQP elements on the FAO APQP
Status Report show that APQP methodologies are understood and
implemented? (Reference Appendix A of the FAO APQP Status
Reporting Guideline)
2. Does the plan address how to improve aspects of the product that
the customer finds satisfactory (i.e. things-gone-right)?
QSA-E 9 January, 1999
Ford Automotive Operations
Technical Capability
QSA-E 10 January, 1999
Ford Automotive Operations
Technical Capability
B. Product Launch
11. Does the supplier have plans to support all pre-Job #1 builds and
launch with representatives who are knowledgeable of the program
and the build/launch procedures?
- Qualified in WERS?
13. Are launch representatives familiar with DVP&R, VDS, SDS, CDS
and all testing/inspection aspects of their components/system as to
be considered an expert and reliable resource to the Ford launch
team?
15. Does the supplier conduct internal "fresh eyes" launch readiness
reviews? Are these reviews a part of the PD process? Do they
involve cross-functional representation?
QSA-E 11 January, 1999
Ford Automotive Operations
Technical Capability
19. Does the PDS support Ford Corporate Design (interior studio
feasibility engineering requirements
- Feasibility Drawing?
- Prototype drawings?
- Math Surface?
- WERS Concerns?
- DVP&Rs?
- SDS/CDS Development?
- Service only Drawings?
- Product timing plans?
- Body Structural Drawings?
- Release (End-Item) Drawings?
- Tolerance Studies?
- Design Check Sheets?
- Illustration?
QSA-E 12 January, 1999
Ford Automotive Operations
Technical Capability
- Sign-off milestones?
QSA-E 13 January, 1999
Ford Automotive Operations
Technical Capability
A. Component Design
1. Are appropriate personnel experienced and qualified in the
following skills:
- Failure Mode Analysis (FMA)?
- Design of Experiments (Taguchi and classical)?
- Problem Solving?
- Design Specifications
- D/P FMEA?
- DVP&R?
- Ford WERS?
QSA-E 14 January, 1999
Ford Automotive Operations
Technical Capability
11. Are appropriate measures planned and implemented for the security
of Ford proprietary information/property (such as designs, computer
software, prototype vehicles, etc.)?
QSA-E 15 January, 1999
Ford Automotive Operations
Technical Capability
B. Prototype Build
17. Does the supplier have a comprehensive prototype program?
C. System Design
22. Is performance testing (life, durability, reliability) tracked for timely
completion and conformance?
23. Does the supplier's product design engineers understand "Key Life
Testing" (based on usage profiles for their systems)? Has the
supplier participated in the development of Real-World Usage
Profiles?
24. Have "Key Life Tests" been identified for specific Ford programs?
Have implementation plans been developed?
QSA-E 16 January, 1999
Ford Automotive Operations
Technical Capability
26. Does the supplier support fit and finish reviews with Ford VO? Is
Ford VO labor to assemble considered and minimized?
27. Has the supplier demonstrated the ability to communicate and work
with suppliers of interacting components in order to develop designs
or resolve issues?
28. Are cross functional team design reviews held to address system
design compatibility issues? Do they support Ford programmed
compatibility reviews?
D. Vehicle Design
31. If applicable, are vehicle design specifications (VDS) used to
develop complete vehicles using program management, engineering
design/development, styling and prototype build disciplines?
QSA-E 17 January, 1999
Ford Automotive Operations
Technical Capability
E. Service Engineering
33. Is serviceability included in design reviews and in the design check
sheets?
34. Has the supplier developed operating and repair procedures for
supplied components? Are service complexity reduction
opportunities identified?
36. Has the supplier visited dealers for on-site review of component
performance and serviceability? Is there an established dealer to
product design information loop?
38. Is the supplier familiar with WERS data requirements for service
end item release and data?
Government Regulations
39. Does the organization have a process to identify all applicable
government safety and environmental regulations, including those
affecting the processes performed?
QSA-E 18 January, 1999
Ford Automotive Operations
Technical Capability
- CAD contact(s)?
- CAD SOW/Checklist?
2. Does the organization provide formatted files and/or CAD data files
throughout the program? Does design output conform to:
- Ford Engineering Drafting Standards
3. Does the organization provide proper documents for release into the
Ford system?
QSA-E 19 January, 1999
Ford Automotive Operations
Technical Capability
(Reference:)
- CEPR (Common Engineering Planning Reporting)
Access program information (i.e. component and event due dates)
(Reference:)
- DESIGN LAYOUT/DETAIL NUMBERING SYSTEM
All numbering of the CAD data files are maintained to current
design level releases as set forth by the specific program.
Reference; Corporate Product System Classification(CPSC)
- GEOMETRY
Complete 3-D data files are submitted in accordance to
requirements as set forth by the specific program.
- DATA EXCHANGE
Interface directly with Ford computer network and systems without
translation adhering to CDX policy.
- RETENTION
Data retention adheres to Corporate Record Management(CRM)
Policy.
QSA-E 20 January, 1999
Ford Automotive Operations
Technical Capability
D. CAE
8. Are appropriate resources and facilities available to effectively use
CAE analysis tools (e.g. FEA) during the concept and development
stages to:
- Achieve required structural, durability, and NVH targets?
- Conduct pre and post CAE analysis reviews with appropriate Ford
engineering activities, when required?
QSA-E 21 January, 1999
Ford Automotive Operations
Technical Capability
D. CAE (continued)
11. Does the organization's CAE analysis library include examples of
failure modes from prior programs? Are CAE failure modes written
into DFMEAs?
13. Does the supplier, where appropriate, have CAE capability for
vehicle analysis in the following areas:
- Crash analysis?
- Ride and Handling?
- NVH?
- Computational Fluid Dynamics (CFD)?
- Acoustics Kinematics?
QSA-E 22 January, 1999
Ford Automotive Operations
Technical Capability
7. Does the supplier have R&D plans which set and prioritize advanced
project objectives? Do the supplier's plans support Ford technology
plans? Are R&D plans included in the supplier's business plan?
QSA-E 23 January, 1999
Ford Automotive Operations
Technical Capability
A. Test Equipment/Facility
1. Have appropriate statistical studies been conducted to analyze the
variation present in the results of each type of measuring and test
equipment system?
2. Are test area energy sources for lighting, heating, humidity, and
ventilation adequate to ensure proper test performance?
QSA-E 24 January, 1999
Ford Automotive Operations
Technical Capability
- Post-test activities?
10. Does the test data reduction, analysis, and presentation comply with
the supplier's test procedures and specified Ford requirements?
12. Does the process for developing test fixtures, gauges, etc. ensure
that:
- Measuring points result from team consensus and agree with
significant feature and control plan content?
13. Are instructions on tests that fail or are interrupted by failed parts
included in all test procedures?
14. Does the laboratory durability testing correlate with actual customer
usage (the where, when, how, and how often)?
QSA-E 25 January, 1999
Ford Automotive Operations
Technical Capability
QSA-E 26 January, 1999
Ford Automotive Operations
Technical Capability
4. Does the supplier actively pursue the use of new and improved
materials and manufacturing processes?
QSA-E 27 January, 1999
Ford Automotive Operations
Technical Capability
Color Approval Element S.9b
QSA-E 28 January, 1999
Ford Automotive Operations
Technical Capability
Manufacturing Engineering Staff Element S.11
4. Does the supplier work with Ford during target development with
the intent to maximize reusability and commonality of facilities and
tooling?
QSA-E 29 January, 1999
Ford Automotive Operations
Technical Capability
Manufacturing Engineering Staff(continued) Element S.11
B. Production Sign-off
7. Is there a documented procedure to facilitate a production readiness
review which includes:
- Process potential/capability?
- Manufacturing process relative to design and production intent?
- Tooling and assembly methods descriptions, line speeds, and
cycle times?
- Production validation quantities run or batch sizes?
- Material descriptions/lot numbers?
C. Tooling Progress
9. Does the supplier develop and maintain Tooling Progress Reports
for each program? Are risk assessments maintained throughout the
tooling design and development?
QSA-E 30 January, 1999
Ford Automotive Operations
Notes
QSA-E 31 January, 1999
Ford Automotive Operations
QSA-E Scoring Summary Sheet
Element Total Comments Element
Questions Point Score
S.1 Voice of the Customer 8
S.2 Advanced Quality Planning 19
S.3 Business Plan 2
S.4 Program Management 21
S.5 Product Design Engineering 41
S.6 CAD/CAE 14
S.7 New Technology/Concepts 9
S.8 Product Testing 19
S.9a Materials, Fasteners, Corrosion
Protection Engineering 8
S.9b Color Approval 1
S.10 Simultaneous Engineering 5
S.11 Manufacturing Engineering 9
QSA-E 32 January, 1999
Ford Automotive Operations
Quality System Assessment for Engineering Organizations
GENERAL COMMENTS
Facility Name
Element No. Comments
Page of
QSA-E 33 January, 1999
Ford Automotive Operations
Notes
QSA-E 34 January, 1999
Ford Automotive Operations
Glossary of Terms Appendix A
QSA-E 35 January, 1999
Ford Automotive Operations
Glossary of Terms Appendix A
QSA-E 36 January, 1999
Ford Automotive Operations
Reference Publications Appendix B
Target Guidelines - - for Ford and FAO, Product Development Finance Process Leadership
Suppliers Group
QSA-E 37 January, 1999
Ford Automotive Operations
Record of Changes and Amendments
Page Number(s)
Date Description Affected Approval Signature
QSA-E 38 January, 1999
Ford Automotive Operations