Control Plan Process Audit Checklist

Stellantis Supplier Operations Guidelines for Compliance Supplier Name / SMLC # / City-State: Part(s): Date of Auditor:
Audit:
Control Plan Process Audit

Audit Rating: "Green" - No Nonconformance found "Yellow" - Less than 20% Nonconformance (%NO) "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 1 2 3 4 5 6 7

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank

Audit Question # Guidelines for Compliance

Operation & process descriptions in the Control Plan should match the
1 Is the operation (name & #) and process description in the
operation & process descriptions carried out/executed on the floor at each
Control Plan consistent with the activities on the floor?
station.

Is the operation (name & #) and process description consistent Operation and process descriptions in the Control Plan should match the
2 with those in the Work Instructions (or called out in Operator operation and process descriptions in the Work Instructions (or called out in
Instructions) on the floor? Operator Instructions) used on the floor.

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Machine, Device, Jig, Tools for mfg. listed in the Control Plan should match
Control Plan consistent with those used in the station/on the
those Machine, Device, Jig, Tools used in station/on the production floor.
production floor?

4 Are all product and process characteristics listed in the Control Product and process characteristics, (I.E.- Safety, Critical, etc.), listed in the
Plan consistent with those in the Work Instructions? Control Plan should match/align with those in the Work Instructions

Is the "Product/Process Specification / Tolerance" defined in

5 Product/Process Specification/Tolerance defined in the Control Plan should
the Control Plan consistent with those in the Work
match/align with those in Work Instructions.
Instructions?

Measurement systems/equipment listed in the Control Plan should

6 Is the measurement systems/equipment listed in the Control
match/align with measurement equipment in the Work Instructions, (I.E.-
Plan consistent with those in the Work Instructions?
gauge/tool descriptions, identifying numbers, etc.)

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations Guidelines for Compliance Supplier Name / SMLC # / City-State: Part(s): Date of Auditor:
Audit:
Control Plan Process Audit

Audit Rating: "Green" - No Nonconformance found "Yellow" - Less than 20% Nonconformance (%NO) "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 1 2 3 4 5 6 7

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan Sample size and Frequency listed in the Control Plan should match/align with
consistent with those in the Work Instructions? sample size and frequency called out in the Work Instructions.

Is there any evidence that the Sample Size and Frequency Evidence of inspections/test data for sample size and frequency should be
8 listed in the Control Plan is the same as being used in the daily the same as called out in the Control Plan. Review hourly/shift audit sheets
production? (in needed).

Is there evidence of the duration that the data is Answer Yes/No to audit question, THEN, Enter in Comments Section how far
9 stored/available? (I.E.- 6 months of data observed. (Make a back evidence is available. Ask to see a data sheet from a day/week/month
note in the Comments Section on the duration of data storage) (only one needed) of production in the past 3 months.

For those characteristics that require SPC, is the process Data should be normal, stable, and in control, (I.E. - No runs, trends, or out of
10 capable (Cp/Cpk >= 1.33) or corrective actions have been control points). In Comments section, provide details of Corrective Actions (if
taken for the occasions when it fell below? applicable)

Are the Error/Mistake Proofing measures listed in the Control

11 Error/Mistake Proofing measure listed in the Control plan should match/align
Plan consistent with what is in the station/on the production
with Error/Mistake Proofing measues being used in the station/on the floor.
floor?

Evidence that the Reaction Plan listed in the Control Plan is being used on
12 Is there any evidence that the Reaction Plan listed in the
the floor, could include: (I.E. - Stop the line; Tag and quarantine the suspect
Control Plan is being used on the floor?
parts (WIP); ANDON signal; Notify team lead/supervisor, etc.).

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations Guidelines for Compliance Supplier Name / SMLC # / City-State: Part(s): Date of Auditor:
Audit:
Control Plan Process Audit

Audit Rating: "Green" - No Nonconformance found "Yellow" - Less than 20% Nonconformance (%NO) "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 1 2 3 4 5 6 7

Operation Description >>>

Severity 7: With an Occurrence of 4 or higher, requires action to be taken to

improve the Prevention and/or Detection to the strongest level possible.
Detection score of "4" means defect does not leave the plant.
Severity 8: With an Occurrence of 4 or higher, requires action to be taken to
improve the Prevention and/or Detection to the strongest level possible.
Detection score of "4" means defect does not leave the plant.
13 Referencing the PFMEA, are all Severity scores of "7" and Severity 8 & 9 & 10: With an Occurrence of "4" or higher, Error & Mistake
higher adequately controlled by Control Plan measures? Proofing must be listed in the PFMEA & Control Plan documents and
identified at the station (respectively). Detection must be "4 or lower".
Severity 9 &10: Detection must be "4 or lower" (via automation / machine
/ E&MP) Severity 10:
With "Safety Critical/Critical designations", must have Detection of "4 or
lower". Detection must be via automation/machine and then be 100%
confirmed with a 2nd Detection.

There is a (7) seven layer approach to this question. A single "NO" answer,
to any layer, requires the audit question to be answered with a "NO".
Layer 1)
Does the PFMEA (Process Failure Modes and Effects Analysis) report the
process interruptions as a risk for every assembly line station/process?
Layer 2) Does the Control Plan contain measures to adequately control the
risk for every assembly line station/process? Layer 3) Do the Work
Instructions for each assembly line station/process instruct the operator to
Referencing the PFMEA, are Maintenance events (both
14 correctly "quarantine and disposition" the part in process at the time of the
planned & unplanned) listed as a risk to all of the processes,
"interruption"? Layer 4) Regarding the Line Start Procedure: Do the Work
and documented in the Control Plan & Line Start Procedure?
Instructions instruct the operator as to the implementation of the Line Start
Procedure after these two events? Layer 5) Does the Reaction Plan
adequately list/cover this event? Layer 6) Does the Operator’s Training
Manual content adequately train the operator, for all of the required action
steps that correspond to each assembly line station/process? Layer 7)
Does the supplier’s Layered Process Audit (LPA) adequately/regularly check
for preparedness for this event that has accounted for multiple recalls across
the various Stellantis vehicle product lines.

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations Guidelines for Compliance Supplier Name / SMLC # / City-State: Part(s): Date of Auditor:
Audit:
Control Plan Process Audit

Audit Rating: "Green" - No Nonconformance found "Yellow" - Less than 20% Nonconformance (%NO) "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 1 2 3 4 5 6 7

Operation Description >>>

There is a (7) seven layer approach to this question. A single "NO" answer,
to any layer, requires the audit question to be answered with a "NO".
Layer 1)
Does the PFMEA (Process Failure Modes and Effects Analysis) report the
process interruptions as a risk for every assembly line station/process?
Layer 2) Does the Control Plan contain measures to adequately control the
risk for every assembly line station/process? Layer 3) Do the Work
Referencing the PFMEA, are power outages (including black Instructions for each assembly line station/process instruct the operator to
15 outs, brown outs, safety light curtain interruptions, etc.) listed correctly "quarantine and disposition" the part in process at the time of the
as a risk to all processes & documented in the Control Plan & "interruption"? Layer 4) Regarding the Line Start Procedure: Do the Work
Line Start Procedure? Instructions instruct the operator as to the implementation of the Line Start
Procedure after these two events? Layer 5) Does the Reaction Plan
adequately list/cover this event? Layer 6) Does the Operator’s Training
Manual content adequately train the operator, for all of the required action
steps that correspond to each assembly line station/process? Layer 7)
Does the supplier’s Layered Process Audit (LPA) adequately/regularly check
for preparedness for this event that has accounted for multiple recalls across
the various Stellantis vehicle product lines.

All in-station gaging should have: Serial numbers; Last calibration date;
16 Is there evidence that in station gaging is validated/calibrated
and/or, Next calibration date; All gaging should be a part of tracked
as required by Stellantis standards?
calibration program, either by plant or program callout.

17 Is it impossible/error-proofed that any in station functional/EOL Verify that any in-station test/validation process(es) have adequate measures
test validation steps can be bypasssed? to prevent bypass.

Is there evidence that the in-station functional/EOL test is Answer Yes/No to audit question, THEN, Enter in Comments section if Red
18 operationally calibrated as required? With Red Rabbit Rabbits, BOB/WOW parts, or Master Parts are used as part of equipment
verification, etc? daily check.

Verify that Red Rabbits, if applicable for this station, are easily accessible
19 Are Red Rabbits available in station as required and clearly
and clearly identified. Use COMMENTS section if other method is used
labelled?
(BOB/WOW, or master part, etc.).

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations Guidelines for Compliance Supplier Name / SMLC # / City-State: Part(s): Date of Auditor:
Audit:
Control Plan Process Audit

Audit Rating: "Green" - No Nonconformance found "Yellow" - Less than 20% Nonconformance (%NO) "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 1 2 3 4 5 6 7

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated Look for an easily accessible and clearly identified "Part Chute, Part
accordingly? Bin/Rack", etc., identified as "Scrap Parts".

Is there adequate lighting (both in lumens and direction to the work being
21 Is lighting adequate in station for Class A Surface performed) to identify the variety of A surface imperfections (gloss, grain,
damage/blemish/off-coloring identification? scratches, flash, orange peel, etc). Only applicable to Class A type parts.
Answer "NA" if the part is not a Class A part by nature.

A revisit to the PFMEA document can: 1) Be a part of a monthly CI tool or

22 Is there evidence that the PFMEA is being revisited within an
Layered Audit program; Be the results of an internal quality audit finding; Be
"every 60 days maximum" time cycle?
the results of a recents GIMs/NCT/ Yard Hold event; and others.

Answer audit question with a YES if it is either by station or by line. Use

Regarding the use of installation tools (Nut drivers, power
23 COMMENTS section to clarify if it is by station or line. Use COMMENTS
screw drivers, etc) is there a PM program/inspection log for
section to elaborate if PM program is for "Tool Presence ONLY", or does the
each station or the line as a whole?
PM also look for "Tool Condition", and/or "Tool Installation Date".

Manual tools (I.E. - Simple screwdrivers or magnets for bonus screw

retrieval, etc) all need to be listed in the Control Plan and Work Instructions
24 for each station. Power tools (I.E. - DC nut drivers, etc.) should be serialized
Is each tool listed and its recalibration date noted?
and tracked in a quality calibration system/log book. Tools requiring
calibration should be serialized and report the last calibration date on the
tool.

If the station has no "machine" content, the perspective is on the station

throughput. Negative factors present at the time of the audit on the station's
machine/process are scored with a Yes or No. If Yes, continue as far as
Has this station machine/ Process Overall Equipment
possible with the subsequent questions using the COMMENTS sections. If
25 Effectiveness (OEE) and throughput remained intact since the
No, then STOP. Use the COMMENTS section to detail: 1) What factors ?
PDR and unaffected by factors such as manpower shortages,
(List highest first, followed by next rank). Use COMMENTS section to detail:
part shortages and COVID protocols?
1) What was OEE at time of the PDR (provide OEE and month/year). 2)
What is the OEE at the time of the CPP audit? If it is unknown at the time of
the audit, it will become a point in the PDCA for the supplier to determine.

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations Guidelines for Compliance Supplier Name / SMLC # / City-State: Part(s): Date of Auditor:
Audit:
Control Plan Process Audit

Audit Rating: "Green" - No Nonconformance found "Yellow" - Less than 20% Nonconformance (%NO) "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 1 2 3 4 5 6 7

Operation Description >>>

Reply to the audit question with a Yes if no historical changes. If the reply is
a No, proceed with this next step using the COMMENTS section: 1) If there
26 Have the machine(s)/process(es) in this station remained have been changes, have there been any Forever Requirements approved
unchanged since the PDR and SOP timeframe? since this station and this assembly line process passed the PDR milestone?
2) Report the "month/year" of the FR approval, along with the nature of the
change. 3) Was the FR correctly executed and monitored?

For COMMENTS in each station, simply start with Question #, I.E.- Q3:
"Then begin the comment/observation". When Next COMMENT is
required, again, in the same station, state the question, I.E- Q13: "Then
Observation or Comments
begin comment/observation". The comments/observation are required
for each "NO" answer to any question, as they serve as the base of the
PDCA.

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations Program: Model Year:

Total Items Audited: Overall
Control Plan Process Audit (# of "YES"+"NO")
0
Nonconformance
(# of "NO") 0 Rating:
#DIV/0!

Audit Rating: "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 8 9 10 11 12 13 14 15 16 17 18

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations Program: Model Year:

Total Items Audited: Overall
Control Plan Process Audit (# of "YES"+"NO")
0
Nonconformance
(# of "NO") 0 Rating:
#DIV/0!

Audit Rating: "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 8 9 10 11 12 13 14 15 16 17 18

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations Program: Model Year:

Total Items Audited: Overall
Control Plan Process Audit (# of "YES"+"NO")
0
Nonconformance
(# of "NO") 0 Rating:
#DIV/0!

Audit Rating: "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 8 9 10 11 12 13 14 15 16 17 18

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations Program: Model Year:
Total Items Audited: Overall
Control Plan Process Audit (# of "YES"+"NO")
0
Nonconformance
(# of "NO") 0 Rating:
#DIV/0!

Audit Rating: "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 8 9 10 11 12 13 14 15 16 17 18

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations Program: Model Year:
Total Items Audited: Overall
Control Plan Process Audit (# of "YES"+"NO")
0
Nonconformance
(# of "NO") 0 Rating:
#DIV/0!

Audit Rating: "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 8 9 10 11 12 13 14 15 16 17 18

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations Program: Model Year:

Total Items Audited: Overall
Control Plan Process Audit (# of "YES"+"NO")
0
Nonconformance
(# of "NO") 0 Rating:
#DIV/0!

Audit Rating: "Red" - 20% or More Nonconformance (%NO)

Enter Op # >>>

Process Step 8 9 10 11 12 13 14 15 16 17 18

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 19 20 21 22 23 24 25 26 27 28 29

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 19 20 21 22 23 24 25 26 27 28 29

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 19 20 21 22 23 24 25 26 27 28 29

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 19 20 21 22 23 24 25 26 27 28 29

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 19 20 21 22 23 24 25 26 27 28 29

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 19 20 21 22 23 24 25 26 27 28 29

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 30 31 32 33 34 35 36 37 38 39 40

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 30 31 32 33 34 35 36 37 38 39 40

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 30 31 32 33 34 35 36 37 38 39 40

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 30 31 32 33 34 35 36 37 38 39 40

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 22 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 30 31 32 33 34 35 36 37 38 39 40

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 23 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 30 31 32 33 34 35 36 37 38 39 40

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 24 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 41 42 43 44 45 46 47 48 49 50 51

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 25 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 41 42 43 44 45 46 47 48 49 50 51

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 26 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 41 42 43 44 45 46 47 48 49 50 51

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 27 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 41 42 43 44 45 46 47 48 49 50 51

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 28 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 41 42 43 44 45 46 47 48 49 50 51

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 29 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 41 42 43 44 45 46 47 48 49 50 51

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 30 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 52 53 54 55 56 57 58 59 60 61 62

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 31 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 52 53 54 55 56 57 58 59 60 61 62

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 32 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 52 53 54 55 56 57 58 59 60 61 62

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 33 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 52 53 54 55 56 57 58 59 60 61 62

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 34 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 52 53 54 55 56 57 58 59 60 61 62

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 35 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 52 53 54 55 56 57 58 59 60 61 62

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 36 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 63 64 65 66 67 68 69 70 71 72 73

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 37 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 63 64 65 66 67 68 69 70 71 72 73

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 38 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 63 64 65 66 67 68 69 70 71 72 73

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 39 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 63 64 65 66 67 68 69 70 71 72 73

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 40 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 63 64 65 66 67 68 69 70 71 72 73

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 41 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 63 64 65 66 67 68 69 70 71 72 73

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 42 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 74 75 76 77 78 79 80 81 82 83 84

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 43 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 74 75 76 77 78 79 80 81 82 83 84

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 44 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 74 75 76 77 78 79 80 81 82 83 84

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 45 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 74 75 76 77 78 79 80 81 82 83 84

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 46 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 74 75 76 77 78 79 80 81 82 83 84

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 47 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 74 75 76 77 78 79 80 81 82 83 84

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 48 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 85 86 87 88 89 90 91 92 93 94 95

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0 0 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 49 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 85 86 87 88 89 90 91 92 93 94 95

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 50 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 85 86 87 88 89 90 91 92 93 94 95

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 51 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 85 86 87 88 89 90 91 92 93 94 95

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 52 of 68

 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 85 86 87 88 89 90 91 92 93 94 95

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 53 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 85 86 87 88 89 90 91 92 93 94 95

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

Chrysler Group LLC -- Purchasing and Supplier Quality 829738779.xlsx 12/19/2024 54 of 68

 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 96 97 98 99 100

Operation Description >>>

Answer Yes (auto-calculated) 0 0 0 0 0

Answer No (auto-calculated) 0 0 0 0 0

Percent Nonconformance (auto-

calculated) Blank Blank Blank Blank Blank

Audit Question #

1 Is the operation (name & #) and process description in the

Control Plan consistent with the activities on the floor?

Is the operation (name & #) and process description consistent

2 with those in the Work Instructions (or called out in Operator
Instructions) on the floor?

Are the Machine, Device, Jig, Tools for mfg. listed in the
3 Control Plan consistent with those used in the station/on the
production floor?

4 Are all product and process characteristics listed in the Control

Plan consistent with those in the Work Instructions?

Is the "Product/Process Specification / Tolerance" defined in

5 the Control Plan consistent with those in the Work
Instructions?

6 Is the measurement systems/equipment listed in the Control

Plan consistent with those in the Work Instructions?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 96 97 98 99 100

Operation Description >>>

7 Is the Sample Size and Frequency listed in the Control Plan

consistent with those in the Work Instructions?

Is there any evidence that the Sample Size and Frequency

8 listed in the Control Plan is the same as being used in the daily
production?

Is there evidence of the duration that the data is

9 stored/available? (I.E.- 6 months of data observed. (Make a
note in the Comments Section on the duration of data storage)

For those characteristics that require SPC, is the process

10 capable (Cp/Cpk >= 1.33) or corrective actions have been
taken for the occasions when it fell below?

Are the Error/Mistake Proofing measures listed in the Control

11 Plan consistent with what is in the station/on the production
floor?

12 Is there any evidence that the Reaction Plan listed in the

Control Plan is being used on the floor?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 96 97 98 99 100

Operation Description >>>

13 Referencing the PFMEA, are all Severity scores of "7" and

higher adequately controlled by Control Plan measures?

Referencing the PFMEA, are Maintenance events (both

14 planned & unplanned) listed as a risk to all of the processes,
and documented in the Control Plan & Line Start Procedure?

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 96 97 98 99 100

Operation Description >>>

Referencing the PFMEA, are power outages (including black

15 outs, brown outs, safety light curtain interruptions, etc.) listed
as a risk to all processes & documented in the Control Plan &
Line Start Procedure?

16 Is there evidence that in station gaging is validated/calibrated

as required by Stellantis standards?

17 Is it impossible/error-proofed that any in station functional/EOL

test validation steps can be bypasssed?

Is there evidence that the in-station functional/EOL test is

18 operationally calibrated as required? With Red Rabbit
verification, etc?

19 Are Red Rabbits available in station as required and clearly

labelled?

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 Control Plan Process Audit Checklist
Stellantis Supplier Operations
Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 96 97 98 99 100

Operation Description >>>

20 Are scrap parts isolated in station and marked/labeled/isolated

accordingly?

21 Is lighting adequate in station for Class A Surface

damage/blemish/off-coloring identification?

22 Is there evidence that the PFMEA is being revisited within an

"every 60 days maximum" time cycle?

Regarding the use of installation tools (Nut drivers, power

23 screw drivers, etc) is there a PM program/inspection log for
each station or the line as a whole?

24 Is each tool listed and its recalibration date noted?

Has this station machine/ Process Overall Equipment

25 Effectiveness (OEE) and throughput remained intact since the
PDR and unaffected by factors such as manpower shortages,
part shortages and COVID protocols?

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 Control Plan Process Audit Checklist

Stellantis Supplier Operations

Control Plan Process Audit

Audit Rating:

Enter Op # >>>

Process Step 96 97 98 99 100

Operation Description >>>

26 Have the machine(s)/process(es) in this station remained

unchanged since the PDR and SOP timeframe?

Observation or Comments

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 1 2 3 4 5 6 7 8

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11 12 13 14 15 16 17 18

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21 22 23 24 25 26 27 28

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31 32 33 34 35 36 37 38

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41 42 43 44 45 46 47 48

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51 52 53 54 55 56 57 58

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61 62 63 64 65 66 67 68

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71 72 73 74 75 76 77 78

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81 82 83 84 85 86 87 88

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91 92 93 94 95 96 97 98

Blank Blank Blank Blank Blank Blank Blank Blank

Yes NO % Nonconformance
Is the operation (name & #) and process description
1 in the Control Plan consistent with the activities on 0 0 #DIV/0!
the floor?
 Is the operation (name & #) and process description
2 consistent with those in the Work Instructions (or 0 0 #DIV/0!
called out in Operator Instructions) on the floor?
Are the Machine, Device, Jig, Tools for mfg. listed in
3 the Control Plan consistent with those used in the 0 0 #DIV/0!
station/on the production floor?
Are all product and process characteristics listed in
4 the Control Plan consistent with those in the Work 0 0 #DIV/0!
Instructions?
Is the "Product/Process Specification / Tolerance"
5 defined in the Control Plan consistent with those in 0 0 #DIV/0!
the Work Instructions?
Is the measurement systems/equipment listed in the
6 Control Plan consistent with those in the Work 0 0 #DIV/0!
Instructions?
Is the Sample Size and Frequency listed in the
7 Control Plan consistent with those in the Work 0 0 #DIV/0!
Instructions?

Is there any evidence that the Sample Size and

8 Frequency listed in the Control Plan is the same as 0 0 #DIV/0!
being used in the daily production?
Is there evidence of the duration that the data is
stored/available? (I.E.- 6 months of data observed.
9 0 0 #DIV/0!
(Make a note in the Comments Section on the
duration of data storage)
For those characteristics that require SPC, is the
process capable (Cp/Cpk >= 1.33) or corrective
10 0 0 #DIV/0!
actions have been taken for the occasions when it fell
below?
Are the Error/Mistake Proofing measures listed in the
11 Control Plan consistent with what is in the station/on 0 0 #DIV/0!
the production floor?
Is there any evidence that the Reaction Plan listed in
12 0 0 #DIV/0!
the Control Plan is being used on the floor?
Referencing the PFMEA, are all Severity scores of
13 "7" and higher adequately controlled by Control Plan 0 0 #DIV/0!
measures?
Referencing the PFMEA, are Maintenance events
(both planned & unplanned) listed as a risk to all of
14 0 0 #DIV/0!
the processes, and documented in the Control Plan &
Line Start Procedure?
Referencing the PFMEA, are power outages
(including black outs, brown outs, safety light curtain
15 interruptions, etc.) listed as a risk to all processes & 0 0 #DIV/0!
documented in the Control Plan & Line Start
Procedure?

Is there evidence that in station gaging is

16 validated/calibrated as required by Stellantis 0 0 #DIV/0!
standards?
 Is it impossible/error-proofed that any in station
17 functional/EOL test validation steps can be 0 0 #DIV/0!
bypasssed?
Is there evidence that the in-station functional/EOL
18 test is operationally calibrated as required? With Red 0 0 #DIV/0!
Rabbit verification, etc?
Are Red Rabbits available in station as required and
19 0 0 #DIV/0!
clearly labelled?
Are scrap parts isolated in station and
20 0 0 #DIV/0!
marked/labeled/isolated accordingly?
Is lighting adequate in station for Class A Surface
21 0 0 #DIV/0!
damage/blemish/off-coloring identification?
Is there evidence that the PFMEA is being revisited
22 0 0 #DIV/0!
within an "every 60 days maximum" time cycle?
Regarding the use of installation tools (Nut drivers,
power screw drivers, etc) is there a PM
23 0 0 #DIV/0!
program/inspection log for each station or the line as
a whole?

24 Is each tool listed and its recalibration date noted? 0 0 #DIV/0!

Has this station machine/ Process Overall Equipment

Effectiveness (OEE) and throughput remained intact
25 since the PDR and unaffected by factors such as 0 0 #DIV/0!
manpower shortages, part shortages and COVID
protocols?

Have the machine(s)/process(es) in this station

26 remained unchanged since the PDR and SOP 0 0 #DIV/0!
timeframe?
 9 10

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19 20

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29 30

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39 40

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49 50

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59 60

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69 70

Blank Blank

79 80

Blank Blank

89 90

Blank Blank

99 100

Blank Blank

% Nonconformance

#DIV/0!
#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!
#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!

#DIV/0!
 = Behind
= O.K.
67
= Completed

PDCA PLANNING WORKSHEET

= Behind
= O.K.
= Completed
Status / Legend 5/Why:
R - Late
Y - Maybe Late Total Measured Improvement of 5 - Why:
G - Completed
PROBLEM / ROOT CAUSE STATEMENT / IMPROVEMENT OPPORTUNITY:

Plant: Department: Completed by: Date Last Modified

MEASUREMENT ACTIONS EFFECTIVE?
PLAN DO CHECK (see Note below)
(CHECK)
Schedule Task Timing Reviewed by:
Status
Item
Initiative Task Responsibility
Date Target Close
Who Date Base
Projected
Actual
Yes No*
No. Opened Date Date Improvement

Y 1

Y 2

Y 3

Y 4
Y 5
Y 6
y 7

Y 8

Y 9
Y 10
Y 11
Y 12
= Behind
Y 13
= O.K.
= Completed
Y 14
Y 15
.12/19/2024 . 67 of 68
 = Behind
= O.K.
68
= Completed

PDCA PLANNING WORKSHEET

= Behind
= O.K.
= Completed
Status / Legend 5/Why:
R - Late
Y - Maybe Late Total Measured Improvement of 5 - Why:
G - Completed
PROBLEM / ROOT CAUSE STATEMENT / IMPROVEMENT OPPORTUNITY:

Plant: Department: Completed by: Date Last Modified

MEASUREMENT ACTIONS EFFECTIVE?
PLAN DO CHECK (see Note below)
(CHECK)
Schedule Task Timing Reviewed by:
Status
Item
Initiative Task Responsibility
Date Target Close
Who Date Base
Projected
Actual
Yes No*
No. Opened Date Date Improvement
Y 16
Y 17
Y 18

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