Corrective Action Plan

Audit Date: Assessor:

Item Number Discrepancy/Failure Correction/Action Plan Corrective/Action Plan Target Date for Completion Closed Date Responsibility

FQA - 183
Supplier On Site Audit Form
FQA - 183
Supplier On Site Audit Form
FQA - 183
Supplier On Site Audit Form
 "0" = No Documented System and No Compliance; "1" = No Documented System but Compliance;
SUPPLIER ONSITE AUDIT FORM "2" = Documented System and Partial Compliance; "3" = Documented System and Full Compliance

General Organization and Management Structure

No. ITEM EVIDENCE/ DOCUMENTATION REQUIRED OBSERVATIONS/NOTES Score Risk CORRECTIVE ACTION

- Organization Chart with key

Is the Management structure and Resource
positions filled
1 allocation sufficient to support all necessary High
- Resources appear adequate to fulfill all tasks
disciplines
- Established plan for succession

- Plant is clean, orderly and well lit

- 5S disciplines are in place
Workplace Health and Safety practices are in
2 - Appropriate machine guarding and safeties are High
place and are consistently adhered to
evident
- No signs of visible pollution or spills

- Posted information is appropriate

Does Management regularly communicate
and current (including Customer Ratings)
3 key operational and performance information High
- Evidence of communication sessions
to all employees
- Employee Suggestion Program

- Goals defined in the Business Plan

Management defines quality and - Goals reflect continuous
4 performance objectives that promote improvement High
Continuous Improvement - Minutes of Management Review Meetings
- Evidence of Cost of Quality Analysis & Tracking

- Job descriptions for all levels of the

Responsibilities and authority are defined organization
5 and evidence supports effective employee - Training Records (Including Contract) High
training - Employee training defined & implemented
- Cross-Training Matrix

- Key personnel have required

knowledge to perform job
requirements
Management has sufficient resources to
6 - Sufficient language skills to support the High
effectively manage Customer Requirements
Customer
- Provision for 24 hour Customer
support

Advanced Product Planning

No. ITEM EVIDENCE/ DOCUMENTATION REQUIRED OBSERVATIONS/NOTES Score Risk CORRECTIVE ACTION

- Records of Design/Drawing Review

Process to ensure detailed Contract Review, - Records of Multi-Function Team Reviews
7 High
including Design and Capability review - Understanding of Significant/Critical
characteristic requirements

- Presence of DFMEA, PFMEA &

Control Plans
Product Realization Process provides clear - Linkage between PFMEA, Control Plan and
8 linkages between Product and Process High
Inspection/Control methods
Design and Control Methods
- 8D methodology links back to PFMEA and
Controls

"0" = No Documented System and No Compliance; "1" = No Documented System but Compliance;
SUPPLIER ASSESSMENT FORM "2" = Documented System and Partial Compliance; "3" = Documented System and Full Compliance

- Presence of critical inspection

equipment
(e.g. CMM, Material Tester etc.)
FQA-183 - Availability to 3rd Party Certified Test
Facilities Released OC-01-07
Supplier On Site Audit Form
- Inspection/Test records to validate testing
- Responses to out of specification conditions

Organization is equipped to support
9 necessary verification, validation and
monitoring of characteristics
- Presence of critical inspection
equipment
(e.g. CMM, Material Tester etc.)
- Availability to 3rd Party Certified Test High
Facilities
- Inspection/Test records to validate testing
- Responses to out of specification conditions

- APQP Documentation meets AIAG

standard
Detailed process for managing Advance - Review submitted PPAP packages for
10 Quality activity and sufficient resources to accuracy and completeness High
manage activity - Organization Chart showing
resources

Process for Senior Review or Program

11 - Program Review Process Flow High
Review of all new Programs
- Records of Program Review Meetings

- Engineering software (e.g. CATIA,

Capability to communicate Product design IGIS etc.)
12 High
and Engineering Data with the Customer - CAE, Moldflow, Stress Analysis etc.

A system in place to define approved - Approved packaging plans

13 packaging and for storage and preservation - Warehouse is clean & orderly High
of product - Packaging ensures protection of product

Organization conducts equipment

14 validation and performs run at rate in - Run-at-Rate or OEE Documents
- High
preparation for production

- Records of Early Product

Process for New Product Launch and
15 Containment High
Containment activities
- Review Pre-Launch Control Plans

- Tier 2/3 Supplier PPAP

- Records of Advance Quality Planning with
Sub-Contractor/Supplier product is controlled Tier 2/3 Suppliers
16 High
to ensure compliance - Records of regular Supplier Audits and
development

Product Realization, Measurement, Analysis & Improvement

No. ITEM EVIDENCE/ DOCUMENTATION REQUIRED OBSERVATIONS/NOTES Score Risk CORRECTIVE ACTION

- PPAP records for purchased

products
- In-coming Inspection
System to ensure conformance of purchased Records/COC
17 - High
product - Approved Supplier List
- Reaction to non-conformance
- Third-Party validation of Material
Certifications

"0" = No Documented System and No Compliance; "1" = No Documented System but Compliance;
SUPPLIER ASSESSMENT FORM "2" = Documented System and Partial Compliance; "3" = Documented System and Full Compliance

- Supplier Performance records

- Records of Supplier response to non-
Adequate and effective Supplier conformance
18 High
Management Process - Supplier Development of poor suppliers
- Process to ensure use of Customer approved
suppliers, when appropriate

- Evidence of Job Instructions posted

FQA-183 on line
- Records of Employee training Released OC-01-07
Supplier On Site Audit Form
- Job Instructions match controls as
defined in Process Control Plans
- Re-Work Instructions
 - Records of Supplier response to non-
conformance
- Supplier Development of poor suppliers
- Process to ensure use of Customer approved
suppliers, when appropriate

- Evidence of Job Instructions posted

on line
Work Instructions for all employees affecting
- Records of Employee training
19 product quality, including for repair and re- High
- Job Instructions match controls as
work operations
defined in Process Control Plans
- Re-Work Instructions

- "First-off" Inspection Records

Controls in place to verify process start up
20 - Records of Job Start-up validation, authorized by High
and job change-over
appropriately designated signature

- Preventive Maintenance Schedule &

Records, including downtime analysis
Effective Machine Preventive Maintenance
21 - Database for spare parts High
System
- Visual condition of equipment
- lack of leaks, grease etc.

System to identify, qualify and control
22
Measuring and Test Equipment
- MSA Records
- Inspection and Gauging identification High
- Calibration stickers and records

Operators are trained and qualified for - Operator Gauge Instructions

any required measurement and tests, - Training Records
23 High
including use of appropriate statistical - Capability charts are current and properly
techniques completed

- Engineering Change Records

- Inspection Instructions are changed to reflect
Process to control and react to changes
24 latest level High
impacting upon Product Realization
- PPAP documents reflect latest level
- Manufacturing Documents at latest level

- Error-proofing on line
Mistake-proofing and error-proofing used to
- Poka Yoke
25 control critical characteristics and ensure High
- Lock boxes for defects
product integrity
- Record of daily verification of error proof

- Records of Audits
Process & Systems Audits to ensure System - Audit Schedule based on process requirements
26 High
Compliance and Improvement (High Customer PPM, Failure Modes etc.)
- Evidence of Lessons-Learned to drive improvement

- Review current 8Ds for completion

- Evidence of CFT to resolve problems
- Record of Customer Non-conformance reports &
27 Effective Problem Resolution process High
status. Evidence of Tracking Log.
- Application of corrective action across all
applicable and similar products

"0" = No Documented System and No Compliance; "1" = No Documented System but Compliance;
SUPPLIER ASSESSMENT FORM "2" = Documented System and Partial Compliance; "3" = Documented System and Full Compliance

Material, Facilities, Logistics & Tooling

No. ITEM EVIDENCE/ DOCUMENTATION REQUIRED OBSERVATIONS/NOTES Score Risk CORRECTIVE ACTION

- EDI Capability
- Scheduling Notices
FQA-183 - Customer Service documents
Released OC-01-07
Supplier On Site Audit Form - Delivery Performance monitored
 - EDI Capability
System to ensure receipt of Customer - Scheduling Notices
28 High
schedules and requirements - Customer Service documents
- Delivery Performance monitored

- Material identified at all stages of

operation (in identified containers)
- Suspect material identified and segregated in a
secure and segregated area
- Proper storage of raw & finished materials
- Evidence of FIFO
- System to monitor inventory levels and
drive reduction
- Lack of visible bottlenecks or material constraints
29 Effective Material Identification and Control High

- Lot Traceability Records

- Receiving Records with Lot Numbers recorded
30 Material and Lot Traceability - Shipping Records indicating Lot Numbers High
- In-process material with Lot Numbers
- Shipped product can be traced back to received
material
- Check for use of Bar Code labeling

- BOM matches labels on finished

Final Dock audits ensure integrity of
goods
31 packaging, Correct Part Numbers and High
- No visible evidence of damage
Engineering Levels
- FIFO

- Asset Tags and Tooling I.D.

System ensures preservation of Customer
32 - Proper tool storage facilities High
Tooling
- Tool Maintenance Records

- Supplier can provide summary of all new & pending

33 Plant Capacities Business and timing of critical dates High
- Current capacity studies and resource planning

High

FQA-183
Released OC-01-07
Supplier On Site Audit Form
 Supplier Assesment
General Guidelines for Conducting Assessments

The
TheSupplier
SupplierAssessment
Assessmentisisto
tobe
beaaprocess
processassessment
assessmentand
andshould
shouldaccurately
accuratelyreflect
reflectthe
theSupplier's
Supplier'sactual
actual
manufacturing
manufacturingand
andquality
qualityprocesses,
processes,as
asevidenced
evidencedononthe
themanufacturing
manufacturingfloor.
floor.The
TheAssessment
Assessmentshould
shouldvalidate
validate
that
thatthe
theday-to-day
day-to-dayoperations
operationscomply
complywith
withthe
therequirements
requirementsdetailed
detailedin
inthe
theAssessment.
Assessment.ItItisisinsufficient
insufficientfor
foraa
Supplier
Supplierto
tohave
havedocumented
documentedprocedures
proceduresonly.
only.

Prior
Priorto
tothe
theaudit
auditdate,
date,aacopy
copyof
ofthe
theSupplier's
Supplier'sQuality
QualityProcedures
Proceduresshould
shouldbebeobtained
obtainedbybyelectronic
electronicfile
fileor
orhard
hard
copy.
copy.The
Theprocedures
proceduresshould
shouldbebereviewed
reviewedprior
priorto
tofinalizing
finalizingthe
theaudit
auditdate
dateininorder
orderto
toensure
ensureall
allassessment
assessment
requirements
requirementshave
haveadequate
adequateprocedures
proceduresdefined.
defined.
The
Theaudit
auditshould
shouldbe beconducted
conductedbybytaking
takingaacurrent
currentproduct
productthat
thatisismanufactured
manufacturedandandreviewing
reviewingthetheprocess
processflow,
flow,
as
as detailed. The Assessor should review the Advance Product Planning process used for the part in question,and
detailed. The Assessor should review the Advance Product Planning process used for the part in question, and
then
thenfollow
followthe
themanufacturing
manufacturingflow
flowfrom
fromreceipt
receiptof
ofraw
rawmaterial
materialthrough
throughmanufacturing,
manufacturing,storage
storageandandshipping.
shipping.
Additional
Additionaldisciplines
disciplinesincluding
includingProblem
ProblemResolution,
Resolution,Testing,
Testing,Re-Work
Re-Worketc.
etc.should
shouldbe
bereviewed
reviewedas aswell.
well.

For
Foreach
eachaudit
auditsection,
section,the
therequired
requiredevidence/documentation
evidence/documentationisisdescribed
describedononthe
theAssessment
AssessmentForm.
Form.Key
Keyor
or
critical
criticalrequirements
requirementsarearehighlighted
highlightedininbold
boldtext.
text.The
TheAssessor
Assessorshould
shouldalso
alsouse
usethe
the"Observations
"Observations&&Notes"
Notes"field
field
to
tohelp
helpclarify
clarifyand
andexplain
explaintheir
theirfindings.
findings.AA"High",
"High","Medium"
"Medium"or
or"Low"
"Low"Risk
Riskstatus
status will
willautomatically
automaticallybe
be
generated
generatedby bythe
thescore
scoreassigned
assignedtotoeach
eachelement.
element.The
TheSummary
SummaryScore
Scorefor
foreach
eachparticular
particularelement
elementwill
will
automatically
automaticallybe bereflected
reflectedononthe
theAudit
AuditCover
CoverPage.
Page.

All
Allareas
areasassessed
assessedas as High
High Risk
Riskmust
musthave
haveaadefined
definedCorrective
CorrectiveAction
ActionPlan
Plandetailed,
detailed,asaswell
wellas
asdates
datesdefined
defined
for
forcompletion,
completion,prior
priorto
toaward
awardof ofany
anybusiness.
business.Aside
Asidefrom
fromthe
the"High"
"High"risk
riskelements,
elements,corrective
correctiveaction
actionshall
shallbe
beat
at
the
the discretion of the Assessor. The goal of Corrective Action is to eliminate all "High" risk elements in additionto
discretion of the Assessor. The goal of Corrective Action is to eliminate all "High" risk elements in addition to
attaining
attainingaascore
scoreof
of80%
80%for
foreach
eachaudit
auditsection.
section.The
The"Corrective
"CorrectiveAction
ActionPlan"
Plan"contained
containedwithin
withinthe
theAssessment
Assessment
file,
file,shall
shallbe
beused
usedto totrack
trackall
allcorrective
correctiveaction
actionactivity.
activity.

Subsequent
Subsequent follow-up
follow-up activity,
activity, and
and subsequent
subsequent Assessments
Assessments to to validate
validate implementation
implementation of of
Corrective
Corrective Action,
Action, shall
shall be
be the
the responsibility
responsibility ofof the
the originating
originating Magna
Magna Group
Group and
and Supplier
Supplier
Quality/Development
Quality/Development Engineer,
Engineer, and
and must
must be
be initiated
initiated with
with the
the award
award ofof business,
business, at
at the
the latest.
latest. If
If
the
the Assessing
Assessing Group
Group does
does not
not source
source business
business with
with the
the Supplier,
Supplier, development
development activity
activity shall
shall become
become
the
the responsibility
responsibility of
of the
the sourcing
sourcing Group/Division,
Group/Division, as as defined
defined by
by their
their Business
Business Rules.
Rules.

ItItisisat
atthe
thediscretion
discretionof
ofthe
theparticular
particularFlex
FlexNNGate
Gatetotobase
basesourcing
sourcingdecisions
decisionson
onthe
thefinal
finalscore
scoreattained.
attained.Each
Each
Groups'
Groups' Business Rules shall define the selection criteria to be used. The aim of an Assessmentisisnot
Business Rules shall define the selection criteria to be used. The aim of an Assessment notsimply
simplythe
the
generation
generationof ofaascore.
score.The
Theultimate
ultimateaim
aimisisto
toidentify
identifyand
andaddress
addressareas
areasof
ofsystemic
systemicfailure
failuredriving
drivingundue
unduerisk
riskto
to
our
ourGroups
Groupsand
andDivisions,
Divisions,and
andtherefore
thereforeproper
properresolution
resolutionand
andclosure
closureof
of"High"
"High"risk
riskitems,
items,isiscritical.
critical.

Assessment
Assessmentresults
resultsare
arefor
forsite-specific
site-specificmanufacturing
manufacturingfacilities.
facilities.IfIfaasupplier
supplierhas
hastwo
twoor
ormore
moremanufacturing
manufacturing
locations,
locations,all
alllocations
locationsrequire
requireaaseparate
separateAssessment.
Assessment.

FQA-183
Supplier Onsite Audit Form
 DATE OF
SUPPLIER ASSESSMENT AUDIT:

ASSESSMENT REFERENCE#: N/A

SUPPLIER NAME: SUPPLIER CONTACT:

ADDRESS / CITY / STATE TELEPHONE #

FAX NUMBER: E-Mail Address

REASON FOR AUDIT: Quality System Audit QUALITY ISSUES X NEW BUSINESS
FOLLOW-UP
ANNUAL ASSESSMENT
ASSESSMENT

N/A
Customer
CUSTOMERS (NON-AUTO): -None PPM NA
(Current)

ANNUAL SALES N/A

CUSTOMERS (AUTOMOTIVE):

CERTIFICATION ISO 14001 CERTIFICATION

DATE Certification DATE

TS CERTIFICATION EXPIRY DATE ISO

CERTIFICATION EXPIRY
DATE
Other

Yes

YES- YES YES

X NO

X NO X NO NO

Has Certification ever been revoked? YES If Yes, State Reason: Y N

X NO Supplier has Liability Insurance?

PRODUCT FOCUS FOR ASSESSMENT

(Optional Comments)
Strengths of Organization:
100

80

60

40

20

0
0 0 0 0 0
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Assessment Completed By:
va
M

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uc
Ad

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&

Name:
od

at
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Pr
io

Group:

M
t
iza

E-Mail:
an
rg

Phone:
O

Approvals (if required by Group): Program Management

Quality Purchasing
Name:
Title:
Signature:

FQA-183
Supplier On Site Audit
 Revision Summary
Previous Level New Level Page # Element # Description

FQA-183
Supplier On Site Audit Form
Description

FQA-183
Supplier On Site Audit Form