Quick Program Snapshot

• Program name, OEM, part number(s) and target SOP date?
• Primary program trigger? Options: New vehicle program (RFQ), Re-source after quality escape/line stop, Bid to replace incumbent at renewal, Cost takeout initiative, Other
• Who is the primary business owner and which procurement role is authorized to sign the award?
• Which stakeholders must be satisfied for award (select all that apply)? Options: Commodity Buyer, Purchasing Manager, Supplier Quality Engineer (SQE), Program Engineering, Materials Planning, Finance, Operations, Other
• How comfortable are you with the current SOP timeline? Options: Very comfortable, Somewhat comfortable, Concerned, Unsure

Are We Betting the Launch on Assumptions?

• What single assumption about cost, capability, or timing—if wrong—would cause this program to miss SOP?
• Has a target piece-price been set and how was it derived? Options: Should-cost model provided, Market benchmarking, Incumbent price, Top-down target from program, No target set, Other
• What target cost band (per piece) would make a supplier competitive for award? Options: <$0.50, $0.50–$1.00, $1.01–$5.00, $5.01–$20.00, >$20.00
• What are the required capability targets for critical characteristics (specify Cp and Cpk targets or enter 'TBD')?
• Which critical characteristics must be demonstrated as capable before award versus those that can be fixed post-award with containment? Options: Fit/Assembly interfaces, Structural safety-critical, Sealing/functional, Surface finish/aesthetics, Dimensional tolerance stack-ups, Other

What Keeps You Up at Night About PPAP?

• If PPAP evidence or timing slips by one month, what are the top three program impacts you fear?
• What PPAP level and deliverables do you require for award readiness? Options: Level 1 - Part Submission Warrant only, Level 2 - Warrant + limited data, Level 3 - Full PPAP (samples + all data), Level 4 - On-site testing, Level 5 - Bulk samples and customer laydown
• When must final PPAP be complete relative to SOP for this program? Options: >=12 weeks before SOP, 8–12 weeks before SOP, 4–8 weeks before SOP, <4 weeks before SOP, No firm requirement
• How are non-conforming PPAP findings handled in your organization (expected containment, rework, stop ship policies)? Options: Immediate containment then corrective action, Stop ship until resolved, Allow limited containment with escalation, Depends on severity / case-by-case
• Tell us about a past PPAP delay you experienced—what happened, who owned it, and how did it change the project?

Where Does Time Hide in Your Supply Chain?

• Which single supplier-side delay has historically caused the biggest program slips, and why?
• What delivery cadence do you require at SOP? Options: Daily JIT (dock-to-line), Multiple weekly deliveries, Weekly, Biweekly, Monthly bulk deliveries
• Which geographic constraints or plant proximity requirements are essential for this program? Options: Within same state/region, <=3 hour truck drive, Domestic only, Cross-border acceptable (customs ok), No constraint
• How much safety stock (if any) are you willing to fund for offshore suppliers? Options: None, 1–2 weeks, 3–6 weeks, >6 weeks, We don't fund safety stock
• What lead time from order release to first production shipment is acceptable at award? Options: <4 weeks, 4–8 weeks, 8–12 weeks, 12–24 weeks, >24 weeks
• Describe any seasonal peaks, launch spikes, or surge scenarios we must design capacity and logistics for (timing and multiples of SOP).

If Cost Could Be Reimagined, What Would You Trade?

• Which trade-off would you accept first to reduce piece-price: material change, process redesign, tooling funding, or delivery terms? Options: Material change, Process redesign (DFM), Tooling cost allocation or co-funding, Longer lead times, Higher batch sizes, Other
• Which specific cost levers are negotiable versus non-negotiable for this program (select all that apply)? Options: Raw material spec, Tooling amortization, Labor content/process steps, Secondary operations, Packaging, Freight terms, Warranty terms
• Are you open to co-funded tooling or NRE to accelerate timing or reduce unit cost? Options: Yes - co-funded tooling acceptable, Maybe - depends on amortization and terms, No - supplier must absorb, Undecided / bring details
• If we propose a net-shape stamping or DFM change that removes secondary operations, how important is preserving incumbent geometry vs realizing immediate cost savings? Options: Preserve incumbent geometry at all costs, Willing to modify for meaningful savings (>10%), Prefer minimal changes but open to negotiation, Fully open to redesign for best value
• Describe a past redesign or DFM win that saved cost—what was sacrificed, who pushed back, and how was alignment reached?

What's the Data You Can Actually Share Right Now?

• If we asked for the RFQ package today, what percentage would you be comfortable sharing immediately? Options: 100%, 75–99%, 50–74%, 25–49%, <25%
• Which of these documents are included in the RFQ package you can share now (select all that apply)? Options: 2D drawings with tolerances, 3D CAD models (STEP/Parasolid), Revision history / ECOs, Material specifications, Forecast (monthly/yearly), Inspection criteria / SPC plans, PPAP checklist / requirements, Failure modes / test reports, Other
• Do drawings include GD&T and control plans for critical characteristics? Options: Yes - complete, Partially - some features covered, No - TBD, Unsure
• What level of forecast granularity do you provide (horizon and resolution)? Options: 36 months, monthly, 24 months, monthly, 12 months, monthly, 6–12 months, weekly or biweekly, Rolling 12 months
• Are there IP, export control, or NDA restrictions that would limit sharing CAD, test data, or supplier lists? Options: Yes - NDA required, Yes - export control restrictions, No restrictions, Unsure - legal review required
• Please summarize any historical failure modes, warranty claims, or audit findings for this part that we should review now.

Let’s Map Decision Reality

• If you had to name one hidden constraint that will ultimately block award, what is it?
• What are the formal decision gates, milestones, and who signs at each gate (names/roles and dates if known)?
• What commercial or financial terms would immediately disqualify a bid? Options: Unacceptable warranty length, Excessive lead times, No capacity commitment, Unapproved sub-tier sourcing, Price above target, Unacceptable payment terms
• What contingency or mitigation plans must be in-place before award (select all that apply)? Options: Tooling completion plan, Sub-tier dual-sourcing, Quality ramp / control plan, Freight contingency, Financial guarantee or escrow, On-site supplier support
• List three measurable criteria you will use to declare a supplier 'award ready' (e.g., Cp/Cpk thresholds, PPAP date met, capacity commitment).
• How will program stakeholders be updated during pre-SOP activities and at what cadence? Options: Weekly status calls, Monthly executive reviews, Shared project portal with dashboards, Ad-hoc emails, On-site reviews / audits

• Solution Experience Intake — Current State & Consequence
• Failure Modes Mapping Workshop
• DFM & Process Controls Proof Session
• Local Footprint & Supply Continuity Workshop
• Validation & Decision Gate — Confirm Future State and PPAP Roadmap

• Define logistics KPIs and any commercial arrangements (consignment, safety stock) needed to realize the future state.
• Host operations to pull machine capability data and historical OTIF metrics for relevant plants.
• Recap Agreed Problems & Proof Scope
• Demonstrate specific, measurable ways DFM and process controls eliminate prioritized failure modes.
• Show the expected cost reduction, lead‑time improvement, and PPAP timeline compression tied to each proof.
• Obtain customer validation for each proof or capture precise gaps for follow‑up.
• Host to deliver annotated CAD redlines, should‑cost delta per part, and a tooling tryout timeline within 3 business days.
• Host quality to produce preliminary SPC charts and proposed control plan template mapped to PPAP elements.
• Customer to confirm that DFM redlines meet functional requirements or provide functional veto items.
• Logistics Constraints & JIT Requirements
• Validate that the host's local footprint meets the customer's JIT and lead‑time constraints.
• Agree a sub‑tier contingency plan that reduces single‑source risk for critical components.
• Introductions & Objectives
• Host to provide plant OTIF data, transit time spreadsheet, and proposed contingency suppliers for critical sub‑tiers.
• Customer to confirm required delivery cadence, dock windows, and preferred carriers for planning.
• Host and customer to model safety stock reduction and associated working capital impact for review.
• One‑Sentence Future State Confirmation
• Customer explicitly validates that the provided proofs achieve the defined future state and KPIs.
• Agree a detailed PPAP roadmap with dates, deliverables, and acceptance criteria mapped to decision gates.
• Secure mutual commitments for commercial assumptions and the date for pilot/PPAP execution.
• Host to deliver final package of validation artifacts (capability reports, control plans, DFM redlines) for customer review and storage.
• Customer to confirm acceptance criteria and provide formal sign‑off or list of remaining objections within 5 business days.
• Schedule tooling tryout and PPAP pilot dates and assign owners for each decision gate.
• Customer and host agree on a single-sentence current state describing the problem.
• Consequence of continuing the current state is quantified in operational terms (cost/time/risk).
• A one‑sentence future state and 2–3 KPIs to prove it are agreed upon.
• All required artifacts and owners for the Solution Experience are identified and committed.
• Customer to upload final RFQ package, latest FMEA, escape reports, and any should‑cost inputs within 48 hours.
• Host to prepare an initial consequence model (cost-of-delay, PPAP slip exposure) using customer inputs.
• Schedule Failure Modes Mapping Workshop and assign facilitator and scribe.
• Scope & Rules of Engagement
• Produce a prioritized list of failure modes tied to quantified impacts.
• Define root cause hypotheses and the exact data/artifacts required to validate mitigation.
• Agree which failure modes will be addressed in the proof session and which are lower priority.
• Customer to provide raw SPC data, sample inspection reports, and any material certificates for prioritized failure modes.
• Host engineering to prepare preliminary DFM change concepts and a mapping of which failure modes each change addresses.
• Evidence Walkthrough
• Local Footprint Proof Points
• DFM Redlines & Process Simplification Proofs
• Pre‑work Verification
• Failure Mode Review
• Impact Mapping
• Current State Statement
• Risk Register & Mitigation Owners
• Tooling & Tryout Plan Linked to PPAP Risk Reduction
• Sub‑tier Sourcing & Contingency Mapping
• Consequence Quantification
• PPAP Roadmap & Decision Gates
• Root Cause Hypotheses & Data Gaps
• Inventory Impact & Commercial Options
• Process Controls & SPC Evidence Path
• Commitments, Next Steps & Executive Alignment
• Define Future State & KPIs
• Tiebacks — Each Proof vs Failure Mode
• Prioritization & Quick Wins
• Agreement on Logistics KPIs and Escalation Paths
• Validation Checks & Customer Confirmation
• Next Steps & Artifact Commitments

• Issue Firm Fixed-Price Quotation
• Build DFM-Optimized Progressive Die Tooling
• Produce Engineering Prototype Parts
• Perform Tool Tryout and Press Tuning Runs
• Provide First Article Inspection (FAI) Samples
• Compile and Submit PPAP Package
• Run Pre-Production Pilot Build (launch lots)
• Apply E-coat and Final Finish Processing
• Assemble and Deliver Trim Module Subassemblies
• Deploy Robotic Assembly Cell for Production
• Provide Just-in-Time Sequenced Line-Side Deliveries
• Execute Surge Production Runs for Peak Demand
• Deliver Certified Subcomponent Kits with Traceability

Issue Firm Fixed-Price Quotation

• Do you require a firm fixed-price quotation for the program? Options: Yes, No
• What pricing validity period do you need (quote hold time)? Options: 30 days, 60 days, 90 days, Custom
• What is the expected annual and peak volume commitment to support fixed pricing? Options: Less than 10k/year, 10k-100k/year, 100k-500k/year, 500k+/year
• Which cost elements must be included in the fixed price? Options: Tooling amortization, Raw materials, Freight/logistics, Warranty reserve, Engineering support, Other
• Are commodity escalation clauses allowed or must price be fully fixed? Options: Fully fixed (no escalation), Indexed/escalation allowed, Hybrid (cap on escalation)
• Who owns exchange rate and duty risk for the quoted price (buyer/seller)? Options: Buyer, Seller, Shared/Specify in comments

Build DFM-Optimized Progressive Die Tooling

• Is a DFM review and progressive die concept required for this part? Options: Yes, No, Partial (select features)
• Who will own tooling capital: supplier, customer, or shared? Options: Supplier owns tooling, Customer owns tooling, Shared cost, Lease/consignment
• What tooling timeline is required to meet program milestones (prototype, tryout, PPAP)? Options: <8 weeks, 8-16 weeks, 16-24 weeks, 24+ weeks
• Please list critical part features or failure modes the die must address (free response).
• What level of tool maintenance/support package is expected post-SOP? Options: Basic (spare parts only), Preventive maintenance plan, Full support with on-site techs, None
• Are any dimensional capability targets (Cp/Cpk) required to guide die design? Options: Yes - specify in comments, No, Not sure

Produce Engineering Prototype Parts

• Do you require engineering prototype parts prior to tooling completion? Options: Yes, metal prototypes, Yes, soft-tooling/plastic prototypes, No
• How many prototype iterations and sample quantity are needed? Options: One iteration (5-20 pcs), Multiple iterations (20-100 pcs), Low volume run (100-500 pcs), Custom
• Which tests must prototypes pass (fit, function, environmental, dimensional)? Options: Fit, Function, Environmental, Dimensional, Durability, Other
• Are prototypes required to be produced at the eventual production site or can they be outsourced? Options: At production site, Outsourced tooling partner, Either
• Who will evaluate and approve prototype test results and sign off for tooling changes? Options: Customer engineering, Supplier engineering, Joint team
• Do prototypes need serial-number traceability or metallurgical certifications? Options: Yes - traceability, Yes - material certs, No

Perform Tool Tryout and Press Tuning Runs

• Will you require on-site tryout at the supplier facility or customer witness at tryout? Options: Supplier-only tryout, Customer witness required, Remote witness allowed
• How many press tuning iterations and run-hours are anticipated? Options: Short (1-8 hours), Medium (8-24 hours), Extensive (24+ hours)
• What target cycle time and scrap rate acceptance should press tuning achieve?
• Are specialized gauges, fixtures, or measuring equipment required during tryout? Options: Yes - supplier provides, Yes - customer provides, No
• Who is responsible for corrective tool modifications discovered during tryout? Options: Supplier, Customer, Shared responsibility
• Do tryout results require formal documentation (run sheets, NCRs, tryout report)? Options: Yes - standardized report, Yes - summary only, No

Provide First Article Inspection (FAI) Samples

• Is a formal FAI required per customer or PPAP standard? Options: Yes - customer FAI, Yes - PPAP FAI, No formal FAI required
• How many FAI samples are needed and in what conditions (as-built, painted, assembly)? Options: 1-5 samples, 6-20 samples, 20+ samples, Specify details
• Which dimensional or functional attributes must be reported in the FAI? Options: Critical dimensions, Functional tests, Material properties, Surface finish, Other
• Do FAIs require accredited measurement labs or in-house CMM capability? Options: Accredited external lab, Supplier in-house CMM, Customer lab
• Are FAI reports required to include traceability to production lot and tool revision? Options: Yes, No, Partial
• Who will approve FAI results and what is the expected approval SLA? Options: Customer (7-14 days), Customer (48-72 hours), Supplier approves

Compile and Submit PPAP Package

• Which PPAP level is required by the customer for submission? Options: Level 1, Level 2, Level 3, Level 4, Level 5
• Which PPAP elements are mandatory (DFMEA, PFMEA, control plan, MSA, SPC, PPF)? Options: DFMEA, PFMEA, Control Plan, MSA, SPC/Capability, Process Flow, Other
• What PPAP submission timeline must be met relative to SOP? Options: >90 days before SOP, 60-90 days, 30-60 days, As negotiated
• Do you require customer witness or on-site audit as part of PPAP acceptance? Options: Yes - witness required, Audit only if issues, No
• Who will own corrective action closure for any PPAP non-conformances? Options: Supplier owner, Customer owner, Joint responsibility
• Are digital submission formats preferred (e.g., PDFs, e-portal upload)? Options: Customer e-portal, Email PDFs, Hard-copy binder, Other

Run Pre-Production Pilot Build (launch lots)

• Will you require defined launch lot sizes and acceptance criteria? Options: Yes - define lots, No - ad hoc, Specify in comments
• What inspection and test coverage is required during pilot builds? Options: 100% inspection, Sample inspection (AQL), SPC monitoring only, Functional testing
• Should pilot builds be delivered to customer lines or retained for internal validation? Options: Deliver to customer, Retain at supplier, Split delivery
• Are containment or segregation controls required during pilot production? Options: Yes - segregation required, No, Only if issues arise
• Who approves transition from pilot to mass production? Options: Customer sign-off, Supplier sign-off, Joint sign-off
• Do pilot builds require full traceability and serialized lots? Options: Yes - serialized, Traceability to lot only, No

Apply E-coat and Final Finish Processing

• Is e-coat finish mandatory for the part or optional? Options: Mandatory, Optional, Not required
• What surface finish specifications and thickness targets are required?
• Are environmental or regulatory certifications required for the finish process (e.g., RoHS, local permits)? Options: Yes - list required, No, Unsure
• Will finishing be performed in-house or by sub-tier coaters? Options: In-house, Approved sub-tier, Customer-specified coater
• Are post-coat inspections (adhesion, thickness, salt spray) required before assembly? Options: Yes - full testing, Sample testing, No
• Do you require special packaging or handling after finishing to prevent marring? Options: Yes - specify, Standard protection, No

Assemble and Deliver Trim Module Subassemblies

• Do you require supplier to perform complete module assembly or deliver component sets? Options: Complete assembled modules, Subassembly kits, Components only
• What assembly test points and functional checks must be completed before delivery? Options: Mechanical fit, Electrical check, Functional cycle test, Visual inspection, Other
• Is customer-provided tooling or fixtures required for final assembly? Options: Yes - supplied by customer, Supplier to provide, No
• What packaging and sequencing requirements exist for line-side installation? Options: Kitted and sequenced, Bulk packaged, Custom packaging
• Are supplier assembly operations subject to customer process audits or workmanship standards? Options: Yes - audits required, Only initial audit, No
• Who owns warranty and responsibility for assembled modules after delivery? Options: Supplier, Customer, Shared per contract

Deploy Robotic Assembly Cell for Production

• Is a dedicated robotic cell required for this part or can manual assembly be used? Options: Dedicated robotic cell, Manual assembly, Hybrid/robot-assisted
• What takt time and cycle time targets must the robotic cell meet? Options: <10s, 10-30s, 30-60s, 60s+
• Will the supplier design, integrate, and qualify the robot cell, or will customer provide specs/standards? Options: Supplier design & integrate, Customer provides specs, Third-party integrator
• Are vision systems, torque controls, or force-feedback required for assembly operations? Options: Vision systems, Torque/force control, None of the above
• What validation and safety certifications are required for the robotic cell (e.g., ISO, UL)? Options: ISO standards, Local safety certs, Customer-specific
• Do you require robotic cell commissioning at the customer site and operator training? Options: Yes - commissioning and training, Training only, No

• Statement of Work (SOW)
• Commercial Terms & Final Pricing
• Purchase Order / Intent to Award
• Lead Time & Delivery Schedule
• PPAP & Validation Schedule
• Tooling & Capital Investment Agreement
• Warranty, Liability & Change Control
• Acceptance Gates & Decision Milestones
• Capacity Reservation & Capacity Commitment
• Sub-tier Sourcing & Audit Commitments
• Payment Terms & Invoicing Schedule
• Performance Guarantees & Remedies
• Confidentiality & Intellectual Property License

• Success Validation Review
• Lessons Learned & Root Cause Workshop
• Continuous Improvement Governance & Issues Channel Setup
• Operational Metrics & Capacity Health Check
• Customer Value Realization / Quarterly Business Review (QBR)

• Publish the updated operational dashboard with filters for critical parts and make it accessible to stakeholders.
• Agree on a prioritized list of corrective and preventive actions with clear owners and verification criteria.
• Capture lessons learned for program playbook updates and feed them into continuous improvement backlog.
• Create and publish corrective action plans (owner, action, due date, verification evidence) into the shared CI channel.
• Update APQP / control plans and tooling documentation to reflect agreed preventive changes.
• Schedule validation trials (e.g., tool tryout, capability run) and assign data collection responsibilities.
• Current Channel & Tooling Inventory
• Create a single, accessible issue and CI channel with clear rules and evidence requirements.
• Define governance, roles, and a regular cadence for triage, escalation, and decision making.
• Set KPI thresholds and automated alerting so problems are detected and escalated before SOP impact.
• Provision the shared channel (CustomerNode workspace) and migrate active issues and supporting evidence into it.
• Publish RACI and meeting cadence; invite triage and escalation team members.
• Configure dashboard alerts for agreed KPI thresholds and assign monitoring owners.
• Opening & Data Pack Confirmation
• Maintain transparent, data-driven visibility into quality and capacity health to prevent operational surprises.
• Early identification of sub-tier or material risks and agreement on mitigation actions.
• Agree alert thresholds and responsibilities for rapid escalation when triggers are met.
• Opening & Objectives
• Assign owners to any risks above threshold and create time-bound mitigation plans.
• Schedule targeted supplier audits or supply risk reviews for flagged sub-tiers.
• Executive Summary: Promises vs Delivered (future state defined)
• Validate and document the customer value realized against original program objectives.
• Resolve or agree next steps for commercial reconciliations and outstanding financial items.
• Secure executive alignment on continued partnership priorities and the CI roadmap.
• Produce a concise ROI / value realization report and distribute to executive stakeholders.
• Document and assign owners for commercial reconciliation items (pricing, warranty, change orders).
• Schedule the next QBR and populate its preliminary agenda with key follow-ups.
• Confirm whether the program meets the pre-defined success signals and formally record acceptance status.
• Quantify consequences for any deviations and agree immediate containment or remediation actions with owners and dates.
• Establish a clear verification plan for any conditional acceptance with pass/fail criteria.
• Publish validated scorecard showing each success signal, measured value, threshold, and final accept/contain decision.
• Assign owners and due dates for all remediation/containment actions and load into the shared issue channel.
• Schedule follow-up validation checkpoint and list required evidence to close each open item.
• Purpose & Prework Review
• Identify root causes tied to evidence and quantify their operational and financial consequences.
• Define Channel Structure and Access Rules
• Incident Facts & Timeline
• Financial Outcomes & Value Delivered
• Quality Capability Review
• Current State Summary (crystal clear)
• Operational Performance: Quality & Delivery
• Success Signals & Acceptance Gates Review
• Root Cause Analysis (structured)
• Governance, Roles & Cadence (RACI)
• Capacity vs Commitment
• Impact & Consequence Quantification
• Continuous Improvement Wins & Roadmap
• Sub-tier & Material Continuity
• Measured Results vs Targets (consequence explicit)
• Triage & Prioritization Process
• Gap Analysis and Root Cause Summary (proof)
• Commercial & Contractual Items
• KPI Alerts & Reporting
• Corrective & Preventive Actions (C/PA) Design
• Delivery Performance & JIT Readiness
• Decision & Remediation Plan
• Immediate Issues Triage
• Risk Register & Trigger Actions
• Validation Plan & Ownership
• Commitments & Next Steps