PlantPilot AI · 2026 Supplier Intelligence

The OEM Scorecard
Survival Guide

Everything automotive Tier 1 and Tier 2 suppliers need to prepare for Ford Q1, GM QSB, and Stellantis SPS audits — and stay audit-ready year-round.

Ford Q1 GM QSB / BIQS Stellantis SPS

FREE GUIDE · NO EMAIL REQUIRED TO READ · IATF 16949 ALIGNED

Introduction
Why OEM Scorecards Keep Plant Managers Up at Night
Ford, GM, and Stellantis each maintain supplier scorecards that directly impact sourcing decisions, program awards, and supplier status. Here's what's at stake.
68%
of Tier 2 suppliers are currently below their OEM's target OEE threshold
$180K+
average cost of a controlled shipping Level 1 event for a mid-size supplier
90 days
typical window from audit failure to sourcing impact if not corrected
📋
What OEM Scorecards Actually Measure
And why most suppliers are measured on things they don't track daily

Every major OEM maintains a supplier scorecard — a running assessment of your plant's quality, delivery, and operational performance. These scorecards determine your supplier status, your access to new program awards, and in some cases your continued position on existing programs.

The three most consequential scorecards for US automotive Tier 1 and Tier 2 suppliers are Ford's Q1 certification, GM's Supplier Quality System (QSB/BIQS), and Stellantis's Supplier Performance Standards (SPS). Each has distinct requirements, different escalation protocols, and different consequences for non-compliance.

What they share: all three reward suppliers who demonstrate structured, documented, and sustained continuous improvement programs — not just good numbers on a given day.

⚠️
The Three Supplier Failure Patterns
How plants with good operations still fail OEM audits

Pattern 1 — The Documentation Gap. The plant is performing well but can't demonstrate it with the documentation the OEM requires. SOPs exist informally. Corrective actions are tracked in spreadsheets. 8D reports are incomplete. When the auditor asks for evidence, the team scrambles.

Pattern 2 — The Reaction Lag. A quality event occurs. The plant responds correctly — but too slowly. Ford's PPM threshold is breached before a formal corrective action is logged. GM's escalation protocol is triggered before the root cause is documented. The problem is solved; the scorecard still takes the hit.

Pattern 3 — The Sustained Improvement Gap. A Kaizen event delivers real results. Changeover time drops. Scrap improves. The audit goes well. Six months later, the gains have eroded and the next audit tells a different story. The OEM sees inconsistency, not capability.

The common thread across all three patterns: the plant's operational capability exceeds its CI infrastructure. The team is good enough — the system supporting them isn't. This guide addresses that gap for each of the three major OEM scorecards.
🔵 Ford Q1
Chapter 01 · Ford
Ford Q1 Certification — What It Measures and How to Stay Certified
Ford Q1 is the highest supplier quality designation Ford awards. It directly impacts program awards, supplier status, and access to Ford business. Here's the full picture.
🏆
What Ford Q1 Actually Is
Beyond the plaque on the wall

Ford Q1 is a certification system that evaluates supplier quality management systems, delivery performance, and continuous improvement capability. Q1-certified suppliers are given preferential consideration for new program awards and are subject to less intensive oversight from Ford's Supplier Technical Assistance (STA) team.

Losing Q1 status — or failing to achieve it — has direct commercial consequences. Ford tracks Q1 status during sourcing decisions and will often require a Q1 commitment as part of new business awards.

Q1 certification is evaluated through Ford's Quality Operating System (QOS) — a structured set of process disciplines that Ford auditors review on-site. The QOS assessment covers eight disciplines, each requiring documented evidence of implementation and sustained results.

📊
Ford PPM — The Metric That Triggers Escalation
Understanding Ford's parts per million thresholds and escalation protocol

Ford measures supplier quality performance in Parts Per Million (PPM) — the number of defective parts per one million shipped. Ford's standard PPM threshold is typically 50 PPM, though this varies by commodity and program.

When a supplier breaches the PPM threshold, Ford's escalation protocol activates automatically:

Threshold Breach
PPM exceeds Ford threshold (typically 50 PPM)
Ford's system flags the breach automatically. The clock starts. Your STA contact is notified.
Within 24 Hours
Containment required — immediate 8D submission
Ford expects evidence of containment within 24 hours of the breach notification. An initial 8D report must be submitted with the first three disciplines completed.
Within 10 Business Days
Root cause and corrective action required
A complete 8D report with verified root cause, corrective actions, and prevention measures must be submitted and accepted by your Ford STA contact.
30–60 Days
Controlled shipping risk if unresolved
Sustained PPM above threshold without acceptable corrective action can trigger Controlled Shipping Level 1 (CS1) — requiring 100% inspection at the supplier's cost. CS1 average cost: $180K+.
90+ Days
Q1 status review and sourcing impact
Sustained PPM issues trigger formal Q1 status review. Q1 revocation is possible. New program awards are at risk.
🤖
PlantPilot AI
Automated PPM Tracking + 8D Report Generation
PlantPilot AI monitors your PPM against Ford's threshold in real time and alerts your team before the threshold is breached — not after. When a quality event occurs, the 8D Report Generator produces a complete, Ford-formatted report in under 60 seconds. The 10-day response window becomes a same-day capability.
⚡
The 5 Most Common Ford Q1 Audit Failures
Based on supplier quality audit patterns across Tier 1 and Tier 2 plants
01
Incomplete or outdated SOPs
SOPs exist but haven't been updated after process changes. Ford auditors check revision dates and cross-reference with production records.
→ PlantPilot AI auto-flags SOP review triggers on process changes
02
8D reports without verified root cause
The corrective action is logical but the root cause wasn't verified with data. Ford requires evidence the root cause is confirmed, not assumed.
→ PlantPilot AI's RCA module requires data-verified root cause before 8D closure
03
Corrective actions not sustained
The fix was implemented but not built into standard work. Six months later the problem recurs. Ford sees this as a systemic failure, not a one-off event.
→ PlantPilot AI's Kaizen & Standard Work module locks corrective actions into SOPs
04
No evidence of CI program structure
The plant is improving but has no documented CI project pipeline to show the auditor. Improvement must be demonstrably systematic, not reactive.
→ PlantPilot AI's DMAIC Project Manager creates a documented CI portfolio automatically
05
PFMEA not updated after defects
A quality defect occurred that the PFMEA didn't anticipate. Ford expects the PFMEA to be updated to reflect the new failure mode. Most plants miss this step.
→ PlantPilot AI prompts PFMEA review and update as part of every 8D closure workflow
✅
Ford Q1 Audit Readiness Checklist
Check each item to track your readiness — progress saves automatically
  • ✓
    Current OEE tracked and documented at machine level
    Ford expects OEE visibility at individual machine or cell level, not just plant-wide averages.
  • ✓
    All SOPs current — revision dates within 12 months or after last process change
    Auditors check revision history. An SOP unchanged for 3+ years with active process changes is a red flag.
  • ✓
    Active 8D process with less than 10-business-day average response time
    Ford expects documented evidence of your 8D response time. Track it. Improve it. Have data ready.
  • ✓
    PFMEA reviewed and updated within last 12 months for all key processes
    PFMEAs are live documents — Ford expects to see evidence they're maintained, not filed and forgotten.
  • ✓
    Active CI project portfolio with documented DMAIC projects and ROI tracking
    At least 2–3 active improvement projects with documented progress is the minimum expectation.
  • ✓
    Corrective actions from previous audits verified closed with sustaining evidence
    Ford auditors revisit prior findings first. Open items from previous audits are the fastest way to fail.
  • ✓
    PPM trend for last 12 months documented and below Ford threshold
    Even if current PPM is good, Ford wants to see the trend. A downward trend with one spike is fine. An improving trend after sustained high PPM is scrutinised.
  • ✓
    5S audit scores documented for all production areas — last audit within 90 days
    Ford auditors often do their own 5S walk. Your documented scores should match what they see on the floor.
🟢 GM QSB / BIQS
Chapter 02 · General Motors
GM Quality System Basics — The 11 Elements Every Supplier Must Master
GM's Quality System Basics (QSB) defines the foundational quality management requirements for all GM suppliers. BIQS — Becoming an Ideal GM Supplier — is the advanced tier. Here's how to navigate both.
🏗️
QSB vs. BIQS — Understanding the Two Tiers
What each level requires and what's at stake

QSB (Quality System Basics) is GM's baseline supplier quality standard — the floor, not the ceiling. Every GM supplier is expected to meet QSB requirements. Failure to meet QSB is treated as a systemic quality risk and can result in escalation, increased oversight, and sourcing impact.

BIQS (Becoming an Ideal GM Supplier) is GM's advanced supplier recognition program. BIQS status indicates a supplier has not only met QSB requirements but has embedded a culture of proactive, data-driven continuous improvement. BIQS suppliers receive preferential treatment in new program sourcing decisions and reduced GM oversight burden.

The path from QSB compliance to BIQS recognition runs directly through your CI program infrastructure — documented DMAIC projects, 5S audit history, corrective action closure rates, and sustained OEE improvement.

📋
The 11 GM Quality System Basics — Mapped to PlantPilot AI
What each QSB element requires and which PlantPilot AI tool addresses it
# QSB Element Audit Focus Priority
01 Containment
PlantPilot AI: 8D Report Generator		 Speed and completeness of containment response when a defect escapes Critical
02 Problem Solving
PlantPilot AI: Root Cause Analysis (Fishbone, 5-Why)		 Evidence of structured root cause methodology — data-driven, not opinion-driven Critical
03 Control Plans
PlantPilot AI: Document Generator		 Current, complete control plans for all significant product characteristics Critical
04 Standardised Work
PlantPilot AI: SOP Library + Standard Work Builder		 SOPs at point of use, operators trained and verified, deviation process defined Critical
05 Error Proofing
PlantPilot AI: PFMEA + Corrective Action Tracker		 Poka-yoke devices in place, verified functional, and documented in PFMEA High
06 Appearance Approval
PlantPilot AI: Document Generator		 Valid AAR on file for all appearance-significant parts, reviewed after process changes Moderate
07 PFMEA
PlantPilot AI: Document Generator + RCA Integration		 Living PFMEA — updated after every failure mode discovery, not just at launch Critical
08 Layered Process Audits
PlantPilot AI: 5S Audit Tool + Action Tracker		 LPA schedule maintained, leadership participation documented, findings closed High
09 Mistake Proofing Verification
PlantPilot AI: Corrective Action Tracker		 Daily/shift verification of poka-yoke functionality — logged and trending High
10 Run at Rate
PlantPilot AI: OEE KPI Dashboard		 OEE at or above target rate — documented with trend data, not spot measurements Critical
11 Continuous Improvement
PlantPilot AI: DMAIC Project Manager + Kaizen Manager		 Active CI project portfolio with documented ROI, linked to strategic plant objectives Critical
⚡
GM QSB Audit Readiness Checklist
Track your readiness against each QSB element
  • ✓
    Containment response SOP documented — response time under 24 hours
    GM expects a documented, practiced containment response process — not an ad-hoc scramble when a defect escapes.
  • ✓
    Last 5 quality events closed with data-verified root cause (not assumed)
    GM auditors will pull your last 5 corrective actions and look for evidence the root cause was verified with data — not just stated.
  • ✓
    All SOPs at point-of-use, current revision, operator sign-off documented
    SOPs in a binder in the office don't count. GM expects laminated, current SOPs at the workstation with operator training records to match.
  • ✓
    LPA schedule active — leadership tier completing audits on schedule
    Layered Process Audits require leadership involvement — Plant Manager, Supervisor, and Team Leader tiers each have audit frequency requirements.
  • ✓
    OEE at or above 85% target — documented with 90-day trend
    85% is the world-class OEE benchmark GM uses as a reference. Trend matters as much as current number — a plant at 79% and improving is viewed differently than one at 82% and declining.
  • ✓
    Active DMAIC project with GM-linked KPI (PPM, OEE, scrap, delivery)
    For QSB Element 11, GM wants to see an active CI project tied to a measurable KPI that matters to GM — not an internal housekeeping project.
  • ✓
    All poka-yoke devices verified functional — daily log current
    GM auditors test poka-yoke devices. If your daily verification log shows the check hasn't been done in 3 days, you're failing QSB Element 9 on the spot.
🔴 Stellantis SPS
Chapter 03 · Stellantis
Stellantis Supplier Performance Standards — OEE, Quality, and Delivery in One Scorecard
Stellantis uses a unified Supplier Performance Standard (SPS) that combines OEE, quality, and delivery into a single supplier score. Here's how it works and what it takes to score well.
🎯
How Stellantis SPS Works
The scoring model, the thresholds, and the consequences

Stellantis measures supplier performance across three dimensions: Quality (PPM, warranty returns, field escapes), Delivery (on-time delivery rate, premium freight incidents), and Production Performance (OEE, downtime, SMED compliance).

These three dimensions feed into a composite SPS score that is reviewed quarterly. Suppliers below the SPS threshold are placed on a Supplier Development plan — a structured improvement program with specific targets and timelines. Sustained underperformance can result in "Q" status — Stellantis's watch list designation that signals sourcing risk.

Unlike Ford Q1, which is primarily a certification, Stellantis SPS is a continuous performance score. There is no "pass once and maintain" model — your score is recalculated quarterly based on actual performance data.

📈
Stellantis OEE Requirements — What "Good" Actually Looks Like
The benchmarks Stellantis uses to evaluate your production performance score

Stellantis measures OEE against the following performance tiers for Tier 1 and Tier 2 suppliers:

85%+
World-class OEE — top-quartile supplier score
75–85%
Acceptable range — Stellantis standard target band
Below 70%
Triggers Supplier Development review — improvement plan required
The SMED Factor: Stellantis pays particular attention to changeover time as a component of OEE. Tier 1 and Tier 2 plants with high-mix, frequent-changeover production are evaluated on SMED compliance — whether changeover times are documented, tracked, and actively being reduced. Plants with no formal SMED program are at immediate risk of a low production performance score regardless of their overall OEE number.
🤖
PlantPilot AI
SMED Tracking + OEE Dashboard for Stellantis Reporting
PlantPilot AI's OEE KPI Dashboard tracks availability, performance, and quality metrics at department and line level with Stellantis SPS reporting in mind. The Kaizen & Standard Work module documents SMED events, tracks changeover time trends, and generates the performance evidence Stellantis expects to see during a supplier development review.
✅
Stellantis SPS Readiness Checklist
The key items Stellantis evaluates in a supplier performance review
  • ✓
    OEE at or above 75% — documented with quarterly trend data
    Stellantis uses 90-day trends, not point-in-time measurements. An upward trend below 75% is viewed more favourably than a declining trend above it.
  • ✓
    SMED program documented — changeover times logged and trending down
    Stellantis expects formal SMED documentation — baseline time, improvement actions, current time, target time. A verbal "we've been working on it" doesn't satisfy the requirement.
  • ✓
    PPM below Stellantis threshold — documented with corrective action history
    Stellantis's quality PPM threshold varies by commodity. Confirm your specific threshold with your Stellantis STA contact and document your performance against it monthly.
  • ✓
    On-time delivery rate above 98% — premium freight incidents documented
    Stellantis tracks every premium freight incident. Three or more incidents in a quarter triggers automatic SPS score reduction regardless of quality and OEE performance.
  • ✓
    Supplier Development action plan current — if previously triggered
    If your plant has been placed on a Stellantis Supplier Development plan, every open action item must be current with documented progress. Missed milestones escalate automatically.
  • ✓
    Active CI project tied to OEE or PPM improvement — with documented baseline and target
    Stellantis expects to see at least one active improvement project with a clear baseline measurement, improvement target, and documented progress timeline.
Chapter 04 · Action Plan
Your 90-Day OEM Audit Readiness Plan
A structured 90-day action plan for suppliers who need to get audit-ready quickly — or who want to move from reactive compliance to proactive excellence.
🔴
Days 1–30 — Foundation
Baseline, gaps, and quick wins
Week 1
Audit your current documentation against OEM requirements
Pull every SOP, PFMEA, control plan, and 8D from the last 12 months. Check revision dates. Identify gaps against each OEM's checklist in this guide. Assign an owner to every gap.
Week 2
Establish your OEE and PPM baseline
If you don't have accurate, automated OEE tracking at machine level — establish it now. Manual OEE tracking is accepted by most OEMs but creates data quality risk. Your baseline is your audit starting point.
Week 3
Run a full 5S audit of all production areas
Score every area against 5S standards. Document the results. Assign corrective actions with owners and due dates. The audit report itself is audit evidence — it shows you have a structured audit process.
Week 4
Close all open corrective actions from previous OEM audits
Auditors always revisit prior findings first. Open items from a previous audit are the fastest way to start a new audit badly. Prioritise these above everything else in Month 1.
🟡
Days 31–60 — Infrastructure
Build the systems that sustain compliance automatically
Week 5–6
Launch at least two formal DMAIC improvement projects
Projects should target OEM-relevant KPIs — PPM, OEE, scrap rate, or changeover time. Document the Define and Measure phases completely. This is your CI program portfolio evidence for Ford Q1 and GM QSB Element 11.
Week 6–7
Update all SOPs and place them at point of use
Revise every SOP that is more than 12 months old or that preceded a process change. New revision date. Operator sign-off records. SOPs physically at the workstation — not in a binder in the office.
Week 7–8
Establish Layered Process Audit schedule — all leadership tiers
Define LPA frequency for each leadership tier. Build the schedule. Start executing and logging. LPA compliance in the first 30 days of the new schedule is itself audit evidence of program implementation.
Week 8
Review and update all PFMEAs for high-risk processes
Every process that has generated a quality escape or a new failure mode in the last 12 months needs an updated PFMEA. Update RPN scores. Verify that detection controls are still current.
🟢
Days 61–90 — Proof
Build the evidence package and do a pre-audit self-assessment
Week 9–10
Run a full internal audit using each OEM's checklist
Use the checklists in this guide as your scoring sheet. Have someone who wasn't involved in the preparation run the audit — they'll find what you've missed. Document every finding and close it before the actual audit.
Week 11
Compile your audit evidence package
Assemble: OEE trend data (90 days), PPM trend vs. threshold, 5S audit reports, DMAIC project status, SOP revision records, LPA logs, corrective action closure evidence, PFMEA update history.
Week 12
Brief your team — every person an auditor might speak to
Auditors talk to operators, supervisors, and team leads — not just the Quality Manager. Every person on the floor should know the plant's CI story, what improvements have been made, and where to find documentation. Prepare a 5-minute brief for every shift.
Audit Day
Walk the floor before the auditor does
On the morning of the audit, do a final walk of every area the auditor will visit. Check 5S. Check SOPs are posted. Check poka-yoke verification logs are current. Small things get noticed. Show you noticed them first.
🤖
PlantPilot AI
Run This Entire 90-Day Plan Autonomously
PlantPilot AI executes every step in this plan — tracking DMAIC project milestones, triggering SOP reviews, running 5S audits, generating corrective action reports, and building the evidence package automatically. Most plants using PlantPilot AI complete a full audit readiness cycle in 60 days rather than 90. The 30-day evaluation period means you can start this plan and see measurable results before any long-term commitment.
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