Pierre DE GALZAIN

PSA Peugeot Citron Quality audit responsible

Khalil LACROIX
AFAQ AFNOR Certification auditor ISO/TS 16949

Auditors training
9th and 10th of April, 2005

Summary of training
1. Context 2. Q631000 Standard 3. Audit guide & methods

Summary of training
1. Context 2. Q631000 Standard 3. Audit guide & methods

1. Context : Summary
1.1 Bases of safety approval 1.2 Organization 1.3 Conditions for audit effectiveness

1. Context : Summary
1.1 Bases of safety approval 1.2 Organization 1.3 Conditions for audit effectiveness

Purposes of safety approval

To ensure the capacity of safety parts suppliers to deliver conforming parts

Who?
Must obtain the approval : each external supplier intending to provide safety parts, for each family of safety parts he would deliver.

Audit Standard
A generic standard, defined in the Q631000 PSA standard, Based on ISO standards, it focuses on requirements which enable the supplier to ensure the process stability.

Requirements of the Standard

Process qualification. Modifications under control. Supplier owing the right part definition (good drawings). Updated process control plan. Effective monitoring of purchased parts. Effective manufacturing process and controls. Will and implemented organization to scrap every nonconforming part and to eliminate the non conformity causes.

Success conditions
The supplier must have an ISO/TS 16949 or ISO 9001 (version 2000) certificate. The audit report does not mention any fact that could affect the conformity of the product. Parts measurements are in conformity. The action plan solves every problem found by the audit.

3 possible conclusions after the audits

To refuse utilization of the suppliers parts : Necessity to use CKD parts. To accept utilization of suppliers parts under condition of acceptance control by IKCO. To accept utilization of suppliers parts.

Supplier calendar
Safety approval is given after a complete audit which proves that the supplier produces : conforming parts, with a stable production process, Safety approval is valid for 3 years. A yearly renewal audit must be done .

Supplier calendar
In case of refusal after the first audit : Refused suppliers may ask for a second chance, that can be planned at least 4 months after the first one. It will be a complete audit. The auditors will also have to check the effectiveness of the action plan.

Responsibilities
Safety approval does not change the responsibilities sharing. Safety approval notification is signed by IKCO, SAPCO and PSA Quality Director. Suppliers are responsible of the quality of the parts that they deliver. SAPCO & IKCO are responsible to manage their suppliers.

1. Context : Summary
1.1 Bases of safety approval 1.2 Organization 1.3 Conditions for audit effectiveness

The committee
IKCO and PSA contribute in the Safety Approval Committee : including members of the Project, the Purchasing and Quality departments that : is endowed with a permanent secretary from PSA ; will define the priorities for audits ; will examine the AFAQ audit reports ; will propose the suppliers to be approved to the concerned directors.

Audit team
It includes 3 members :
A Lead Auditor

an AFAQ auditor a SAPCO auditor a project team expert (optional)

An Auditor

Part Expert

1. Context : Summary
1.1 Bases of safety approval 1.2 Organization 1.3 Conditions for audit effectiveness

Audit preparation
The SAPCOs auditor and Project team expert must have studied before the audit, and take with them for the audit : Drawings of parts Technical specifications of parts Control plan Dossier of initial samples , conformity of actual drawings and process SAPCO and IKCO feedback about delivered parts quality.

Summary of training
1. Context 2. Q631000 Standard 3. Audit guide & methods

Requirements of Q631000 Standard

A Control of the product, the process and modifications B Control of documents and data C The suppliers purchases D Product identification and traceability E Process and inspection F Verification of measurement apparatus G Control of nonconforming product. Corrective actions H Internal audits

A - Control of the product, the process and modifications

The supplier defined a modification procedure of product and process
Providing for qualification of the modified process. Consistent with their client's rules for manufacturing and for submitting initial samples.

The supplier does not transfer any production without obtaining their client's written approval.

B - Control of documents and data

The supplier applies a control and internal distribution procedure for their client's documents. Data relating to the product and to the associated processes is available to those who need it.

C - The supplier's purchasing

The supplier guarantees that the product purchased from his sub-contractors is in compliance with the requirements specified by his clients. The supplier measures the quality of the purchased product and the performance of his sub-contractors.

C - The supplier's purchasing

The supplier carries out acceptance inspections at frequencies and in accordance with sampling rules that are appropriate to the quality of the product received from their sub-contractors and to the risks relating to the product. The supplier transmits to his sub-contractors data that clearly describes the applicable specifications, plans and special requirements, and keeps it updated with all modifications.

D - Product identification and traceability

At reception, during the production and at delivery, the supplier applies rules for product packaging, identification and storage preventing any risk of mixture of materials or components. The supplier implements a traceability system depending upon the size of the nonconforming lots returned from the client with respect to the number and characteristics of the faulty products delivered.

E - Process and inspections

The supplier possesses a description of their manufacturing process, including the product inspections. The supplier guarantees the compliance with the quality level specified by the client by ensuring that:
The installations he uses have the appropriate capabilities to achieve the specified tolerances, He complies with the rules communicated by the client to calculate and verify these capabilities,

E - Process and inspections

Supplier implements a suitable monitoring of the operating parameters of the equipments, He carries out inspections and tests of the product at frequencies and on samples calculated according to the performance of the equipments and to the results to be obtained.

E - Process and inspections

The supplier: qualifies his manufacturing processes, trains and qualifies the operators and inspectors in accordance with defined rules makes the work instructions available to staff so that they have all the information required to produce product that is in compliance;

E - Process and inspections

The supplier: keeps an updated process log-book, in accordance with defined rules, in which he records, in particular, all failures, whether they affect the product or the process, and the decisions taken to correct them; defines final inspection rules.

F - Verification of measurement equipments

The supplier complies with the rules communicated to him by the client for the verification of the measurement equipments used for the product or the process at the various manufacturing stages.

G - Control of nonconforming product & Corrective actions

The supplier separates all nonconforming products in secure boxes or closed areas. He ensures that the nonconforming products are identified either by labels or by permanent marking. No nonconforming product must be seen without its immediate and clear identification of this status. The supplier shall remove, daily, all rejected products from the workshop.

G - Control of nonconforming product & Corrective actions

The supplier shall assign qualified persons for the regular analysis of nonconforming products, undertakes, completes and records corrective actions after every failure recorded by the client and to eliminate the causes of the non-compliances reported most frequently, checks the effectiveness of these actions.

H - Internal audits
The supplier's schedule will include, in one or more audits, all the requirements of this Standard. The audit reports are distributed to top management, which regularly monitors the progress of the necessary action plans.

The Assessment Report

ASSESSMENT OF SAFETY PARTS SUPPLIER

STANDARD : PSA Q631000
SECURITY AGREEMENT OF EXTERNAL SUPPLIERS OF SECURITY PARTS FOR MOTORCARS OF PSA PEUGEOT CITROEN GROUP

COMPANY

ADDRESS

Audit Date(s) :
Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CRTIFICATION, its assignees, is illegal

AFAQ AFNOR
CERTIFICATION
Audit Report

PSA Q631000 SECURITY AGREEMENT AUDIT REPORT

Name of the company : Audit date(s) : Address of audited site (s) : Activity concerned by the audit : Reference of the part(s) concerned by the audit : SUMMARY Number of sheets 1. 2. 3.1 3.2 3.3 3.4 Cover page and summary Comments memorandum of Lead auditor New Major Nonconformance form(s) Major Nonconformance form(s) from the previous report (for additional audit) New Minor Nonconformance form(s) Minor Nonconformance form(s) from the previous report (for additional, follow up or renewal audit) Appendices summary : A.1 A.2 A.3 A.4 Closing minutes List of main documents examined on site Audit plan On site inspection report

TOTAL ontact person of the Audited Company Function Auditor tor

Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal

Name : Function : Telephone N: AUDIT TEAM Auditor name

E-mail: Fax N Date : Visa

AFAQ AFNOR
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Audit Report

SUMMARY COMMENTS
1/
Part(s) Reference:

Company

Standard : Safety Agreement PSA Reference : Q631000

General Conclusion :

Date:

- Characteristics, reference of the parts or sub assemblies inspected on site :

- Characteristics, reference of the parts sampled for testing by an independent laboratory

Documents and Data control

- Description of product inspection

- Design and development of products, if any; Product, process and modifications control

- Manufacturing process validation;

- Purchasing

Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal

AFAQ AFNOR
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Audit Report

SUMMARY COMMENTS
Quality system specificities
Part(s) Reference:

Company

2/

Standard : Safety Agreement PSA Reference : Q631000 Reception of products and its inspection

Product identification and traceability

Production and inspection (product samples to be measured in the supplier laboratory, then to be taken to the SAPCO laboratory)

Verification of inspection and measurement equipments

Control of nonconforming products

Corrective actions

Internal audits (if any)

Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal

AFAQ AFNOR
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Audit Report

NONCONFORMITY N
Company :

Major Minor

Page:

Standard : Safety Agreement PSA Reference : Q631000

1 THE NONCONFORMITY SUBJECT : A S S E S S O Does the nonconformity affect a safety characteristic : R
NAME of Auditor : LA Signature :

Requirement reference :

PROPOSED CORRECTION(S) AND/OR CORRECTIVE ACTIONS :

The organization must always give details of the corrective action even when a document which is the result of this corrective action is enclosed.

O R G A N I Z A T Target date : I O NAME of the organization representative : N 3 L A

Name of the party responsible for action : Signature : Pertinent DATE : Non pertinent

COMMENTS CONCERNING THE ORGANIZATIONS ANSWER :

NAME of the LA :

Signature:

DATE :

NONCONFORMITY MODIFICATION DECIDED BY THE SAFETY COMMITTEE :

............................................................................................................................................... ...............................................................................................................................................

Date : Signature :

Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal

AFAQ AFNOR
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Audit Report

Company

CLOSING MEETING
Part(s) Reference:

Standard : Safety Agrement PSA Reference : Q631000

LIST OF PERSONS WHO TOOK PART IN THE AUDIT CLOSING MEETING NAME and first name FUNCTION SIGNATURE

Number of Major Nonconformities : Organization representatives comments :

Number of Minor Nonconformities :

The organization representative acknowledges having read the content of the present report and the content of the major and /or minor nonconformities listed above and may mention his/her disagreement knowing that the Safety Accreditation Committee alone is empowered to decide whether or not to grant the requested accreditation or its maintenance or renewal.

Date : Audit team :

Signature of the organization representative :

Taking into account the documents presented, the installation inspected and the answers provided to the questions asked, the auditors declare, if such is the case, that they conducted their assignment under satisfactory conditions. The signature of the auditors in no case commits their personal responsibility or that of their employer in case of incidents, accidents or errors committed by the organization after the certificate is awarded.

Date :

Signature of the auditor(s) :

Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal

AFAQ AFNOR
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Assessment Report

DOCUMENTS REVIEW
(partial audit preparation) Company : Page: /

Standard : Safety Agreement PSA : Q631000

To be transmitted to the organization, to the audit team and to AFAQ AFNOR CERTIFICATION. 1 - COMMENTS ON EXAMINED DOCUMENTS

Listing of the documents & data available for the Lead Auditor : - name of the involved entities , - drawings of the manufactured parts (involve in the safety approval), - addresses and data of each involved entity - state of acceptance of Initial Samples (IS), - contact name within the organization, - technical specifications, - supplier scope and involved product, - quality failure involving the supplier (given by Iran Khodro & SAPCO) - number of employees of the company, - control plan of the company,

2 - GENERAL CONCLUSION (Scope and limits, audit feasibility...)

LA signature :

VISA :

DATE :

Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal

AFAQ AFNOR
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Audit Report

Audit Plan (Audit Preparation)

Part(s) Reference: yes no

1/

Standard : Safety Agrement PSA Reference : Q631000

The document review has been done. The assessment can be done LA signature : Audit date: Company Name : Audited Site(s) : Date/ Hour Chapter

Date : Auditor(s) involved : LA : A: Observer : * Precise the audited site(s) name and Concerned chapter Site: Opening meeting Site visit Audit Team Audited Persons & Functions

4.1.2

Documents review Control of documents and data Lunch

4.1.1

Design and development of products, if any Product, process and modifications control Purchase Reception of products and its inspection Product identification and traceability Production and inspection (product samples to be measured in the supplier laboratory, than to be taken to the SAPCO laboratory) Verification of inspection and measurement equipments Control of nonconforming products Corrective actions

4.1.3 4.1.5 4.1.4 4.1.5

4.1.6 4.1.7

4.1.8

Internal audits (if any) Pre-closing meeting Closing meeting

AFAQ AFNOR
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Audit Report

Audit Plan (Audit Preparation)

Part(s) Reference: Audit Team * Precise the audited site(s) name and concerned chapter

2/

Standard : Safety Agrement PSA Reference : Q631000 Date/ Hour Chapter

Audited Persons & Functions

Date of the audit planning :

AFAQ AFNOR
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Audit Report

PROPOSAL FORM TO COMMITTEE

(not to be included in the audit report but to be transmitted only to the committee after the audit has been conducted and organizations answer audit)

Company

Standard : Safety Agreement PSA : Q631000

Part(s) Reference:

The LA, after agreement from the other auditors who took part in the present assignment and on the basis of the information gathered, suggests one of the following option to the CC :

AT THE CONCLUSION OF AN AUDIT :

INITIAL FULL RE-AUDIT

- delivery of security agreement

- organization of a full re-audit AT THE CONCLUSION OF A RENEWAL OTHER Assessment (specify): - Safety Security Agreement renewal (subsequent to a renewal audit) ADDITIONAL / UNDER CONTROL

- notification of a sanction (suspension - withdrawal - non-renewal)

Explanation of the proposal :

Any difficulties encountered in the interpretation of the reference standard, the application guide, if it exists, and/or in the context of carrying out the audit have to be explained on page 3.

LA signature :

VISA :

DATE :

Any reproduction or copy, whether whole or partial, made without the authorization of AFAQ AFNOR CERTIFICATION, its assignees, is illegal