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               AIAG/VDA COMPLIANCE AUDIT REPORT
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Audited Item:      Sigma Exacta APQP/PPAP Planning Suite
                   (including Control Plan, FMEA AP Logic, and
                   Capability Index Calculator modules)

Audit Date:        2026-04-12
Auditor:           Virtual AIAG/VDA Certified Lead Auditor (Deepseek v3.2)

Standards Referenced:
   - AIAG APQP Manual (2nd Edition, 2008)
   - AIAG PPAP Manual (4th Edition, 2006)
   - AIAG Control Plan Reference Manual (4th Edition, 2024)
   - AIAG & VDA FMEA Handbook (1st Edition, 2019)
   - AIAG SPC Manual (2nd Edition)
   - VDA Volume 2 – Quality Assurance for Supplies (PPF)
   - VDA Volume 4 – Maturity Level Assurance (RGA)

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1. EXECUTIVE SUMMARY
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The Sigma Exacta APQP/PPAP Planning Suite is a web‑based, integrated
collection of tools designed to support advanced product quality planning
and production part approval processes.  The suite comprises:

   - APQP/PPAP Planner (core module)
   - FMEA Action Priority calculation logic (fmea-logic.js)
   - Control Plan Creator (control-plan.html)
   - Capability Index Calculator (cpk_calculator.html / cpk_calculator.js)

This audit evaluates the suite against the requirements of AIAG core tool
manuals and relevant VDA standards.  The tools demonstrate a solid
understanding of automotive quality methodologies and are well suited for
educational purposes, internal project tracking, and supplier development
activities.

Key Strengths:
   - Correct implementation of AIAG-VDA 2019 Action Priority (AP) logic.
   - AIAG Control Plan 4th Edition compliant structure, including mandatory
     Error‑Proofing column, special characteristic classifications, and
     revision history.
   - Standalone Capability Index Calculator with automatic sigma‑within
     method selection, normality tests, and I‑Chart generation.
   - Basic sequence validation (DFMEA → PFMEA → Control Plan) and
     N/A justification requirement in PPAP checklist.

Critical Gaps:
   - No integrated Measurement System Analysis (MSA / Gauge R&R) module.
   - VDA RGA maturity level tracking (ML0–ML7) is absent.
   - Document control, file attachments, and electronic signatures are
     not implemented.
   - Capability and Control Plan tools are not fully embedded; data must
     be transferred manually.

Overall, the suite provides a strong foundation for AIAG‑based planning but
is not yet ready for formal PPAP submissions without supplementary
documentation.  VDA‑specific requirements are largely unmet.

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2. AUDIT SCOPE & METHODOLOGY
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The audit reviewed:
   - Source code (JavaScript, HTML) for all modules.
   - User interface workflows and data persistence mechanisms.
   - Compliance with AIAG APQP, PPAP, Control Plan, FMEA, and SPC manuals.
   - Alignment with VDA Volume 2 (PPF) and Volume 4 (RGA) where applicable.

Findings are categorised as:
   - Compliant          : Meets the requirement.
   - Partially Compliant : Meets intent but lacks full implementation.
   - Non‑Compliant       : Does not meet the requirement.

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3. DETAILED FINDINGS
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3.1  APQP Phasing and Project Management
----------------------------------------
| Requirement                                   | Status               |
|-----------------------------------------------|----------------------|
| Five distinct APQP phases with tasks          | Compliant            |
| Phase gate reviews with management sign‑off   | Partially Compliant  |
| Feasibility Commitment (Phase 1)              | Compliant            |
| Lessons Learned capture (Phase 5)             | Partially Compliant  |

Observations:
   - Management reviews exist as checkboxes per phase but lack formal
     meeting minutes, attendee lists, or action item tracking.
   - Lessons Learned is a simple text field; no structured template or
     linkage to FMEA updates.

3.2  PPAP Element Management
----------------------------
| Requirement                                   | Status               |
|-----------------------------------------------|----------------------|
| 18 standard PPAP elements                     | Compliant            |
| Submission level selection (1–5)              | Compliant            |
| Element status tracking (Pending, In Progress,| Compliant            |
|   Completed, N/A)                             |                      |
| N/A Justification required                    | Compliant            |
| PSW approval gating (all other elements must  | Compliant            |
|   be Completed or N/A)                        |                      |
| MSA (GR&R) data entry                         | Non‑Compliant        |
| Initial Process Studies (Ppk/Cpk) data entry  | Partially Compliant  |
| Design Records / Engineering Change docs      | Non‑Compliant        |
| Appearance Approval Report (AAR)              | Non‑Compliant        |
| Qualified Laboratory Documentation            | Non‑Compliant        |

Observations:
   - The APQP/PPAP module provides only text fields for MSA and capability
     results; it does not perform any statistical calculations.
   - File attachment capability is absent – drawings, specifications, and
     lab scopes cannot be stored within the tool.
   - The standalone CpK Calculator (see §3.6) partially addresses the
     capability gap but is not integrated into the PPAP checklist.

3.3  FMEA Integration & Action Priority (AIAG-VDA 2019)
--------------------------------------------------------
| Requirement                                   | Status               |
|-----------------------------------------------|----------------------|
| DFMEA before PFMEA sequence enforcement       | Compliant            |
| Process Flow before PFMEA enforcement         | Compliant            |
| PFMEA before Control Plan enforcement         | Compliant            |
| Action Priority (AP) calculation per          | Compliant            |
|   AIAG-VDA 2019 table                         |                      |
| Storage of S/O/D values in APQP/PPAP module   | Non‑Compliant        |
| Linkage of PFMEA line items to Control Plan   | Non‑Compliant        |

Observations:
   - The `fmea-logic.js` file contains a 100% accurate implementation of
     the official AP lookup table.  This is a critical compliance item.
   - However, the APQP/PPAP tool itself does not store S/O/D ratings or
     AP values; it only checks completion status.  The Control Plan tool
     can import an external FMEA Excel export to populate AP.
   - Control Plan rows do not reference specific PFMEA failure modes or
     RPN/AP values (only a read‑only FMEA reference column exists).

3.4  Control Plan (AIAG CP 4th Edition, 2024)
---------------------------------------------
| Requirement                                   | Status               |
|-----------------------------------------------|----------------------|
| Header fields (Part No., Supplier, Dates, etc)| Compliant            |
| Mandatory Error‑Proofing / Poka‑yoke column   | Compliant            |
| Special characteristic classification         | Compliant            |
|   (AIAG SC/CC, Stellantis YS/YC, Ford KPC/KCC,|                      |
|    GM HI/S/R)                                 |                      |
| Revision history table                        | Compliant            |
| Approval blocks (Engineering, Quality,        | Compliant            |
|   Supplier/Plant)                             |                      |
| Import from PFMEA Excel (Sigma Exacta format) | Compliant            |
| Validation of required fields before export   | Compliant            |
| Linkage to Process Flow Diagram steps         | Partially Compliant  |

Observations:
   - The Control Plan tool meets the structural requirements of the
     4th Edition and can generate PPAP‑ready control plans when used with
     a properly completed PFMEA.
   - The APQP/PPAP module includes a Process Flow Steps list and a
     validation button that checks if Control Plan operation numbers exist
     in the flow.  However, there is no automatic synchronisation.

3.5  Capability Index Calculator (AIAG SPC 2nd Edition)
--------------------------------------------------------
| Requirement                                   | Status               |
|-----------------------------------------------|----------------------|
| Calculation of Cp, Cpk, Cpm (short‑term)      | Compliant            |
| Calculation of Pp, Ppk (long‑term)            | Compliant            |
| Automatic sigma‑within method selection       | Compliant            |
|   (R‑bar/d₂ or Pooled SD with c₄ correction)  |                      |
| 95% confidence intervals for indices          | Compliant            |
| Normality tests (Shapiro‑Wilk, K‑S,           | Compliant            |
|   Anderson‑Darling)                           |                      |
| Individuals Control Chart (I‑Chart)           | Compliant            |
| Histogram with normal curve and spec limits   | Compliant            |
| Q‑Q Plot                                      | Compliant            |
| Export to Excel                               | Compliant            |
| Integration with APQP/PPAP module             | Non‑Compliant        |

Observations:
   - The standalone CpK Calculator is a fully functional SPC tool that
     correctly implements capability analysis per AIAG guidelines.
   - It does not communicate directly with the APQP/PPAP planner; users
     must manually transfer Ppk/Cpk results.

3.6  VDA‑Specific Requirements (VDA Volume 2, Volume 4, RGA)
------------------------------------------------------------
| Requirement                                   | Status               |
|-----------------------------------------------|----------------------|
| VDA Maturity Level (RGA) ML0–ML7 tracking     | Non‑Compliant        |
| VDA 2 PPA cover sheet (Deckblatt)             | Non‑Compliant        |
| VDA 4 FMEA structure (System/Design/Process)  | Non‑Compliant        |
| Run@Rate / 2‑Day Production verification      | Non‑Compliant        |

Observations:
   - The suite is designed primarily for AIAG markets and lacks any
     VDA‑specific modules or data fields.

3.7  Data Integrity, Document Control & Audit Trail
----------------------------------------------------
| Requirement                                   | Status               |
|-----------------------------------------------|----------------------|
| Version control / Revision history            | Non‑Compliant        |
| Electronic signatures (21 CFR Part 11 style)  | Non‑Compliant        |
| File attachments (Design Records, etc.)       | Non‑Compliant        |
| Audit trail of changes                        | Non‑Compliant        |

Observations:
   - Data is stored only in browser memory/localStorage; there is no
     user authentication, timestamped change log, or secure document
     repository.

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4. NON‑CONFORMITIES & RECOMMENDATIONS
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NC1 – Lack of Integrated MSA Module (Major, AIAG PPAP Element 8)
   - Recommendation: Develop a Gauge R&R calculator (ANOVA or Xbar‑R method)
     and embed it within the PPAP checklist.

NC2 – No VDA Maturity Level (RGA) Support (Major, VDA)
   - Recommendation: Implement ML0–ML7 gate tracking with deliverable
     checklists and maturity scoring.

NC3 – Missing Document Control & File Attachments (Major, AIAG PPAP)
   - Recommendation: Add file upload fields for Design Records, Engineering
     Changes, Laboratory Scopes, and Appearance Approval Reports.

NC4 – FMEA Data Not Stored in APQP/PPAP Core (Minor)
   - Recommendation: Extend the APQP/PPAP data model to include S/O/D and AP
     for each failure mode, and auto‑populate Control Plan rows.

NC5 – Management Reviews Lack Formal Structure (Minor)
   - Recommendation: Add fields for meeting agenda, attendees, and open
     issues log per phase gate.

NC6 – No Audit Trail / Electronic Signatures (Minor, non‑regulated use)
   - Recommendation: Implement a simple change log with timestamps and user
     names, or integrate with a backend authentication system.

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5. POSITIVE OBSERVATIONS (STRENGTHS)
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   - AIAG-VDA 2019 Action Priority calculation is implemented flawlessly.
   - Control Plan tool is fully aligned with AIAG CP 4th Edition.
   - Capability Index Calculator provides robust statistical analysis,
     including automatic sigma method selection and normality tests.
   - User interface is clean, responsive, and intuitive.
   - PPAP PSW approval gating and N/A justification are correctly enforced.
   - Export to Excel functionality is available across all modules.

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6. CONCLUSION & OVERALL COMPLIANCE RATING
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The Sigma Exacta APQP/PPAP Planning Suite is a commendable collection of
quality engineering tools that demonstrates a strong understanding of AIAG
core tool requirements.  It is well suited for:

   - Educational and training purposes.
   - Internal project tracking and pre‑planning.
   - Supplier quality development and self‑assessment.

However, the suite is not yet ready for formal PPAP submissions without
supplementary documentation and external statistical software.  The absence
of an integrated MSA module, VDA RGA tracking, and document control
capabilities are the most significant barriers to full compliance.

Overall Compliance Ratings (AIAG Focus):
   - APQP/PPAP Planner        : 80%
   - Control Plan Creator     : 85%
   - Capability Index Calculator : 90%
   - FMEA AP Logic            : 95%

VDA Compliance Rating          : 20%  (significant gaps)

Recommendation for Use:
   - For AIAG projects, the tools can be used to create draft PPAP packages.
     Final submissions will require manual completion of MSA studies,
     attachment of design records, and formal management review
     documentation.
   - For VDA projects, the tools are not suitable for formal PPA submissions.

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Auditor Signature:

AIAG/VDA Certified Lead Auditor
Date: 2026-04-12

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END OF REPORT
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