ADVANCE PRODUCT QUALITY PLANN

BENEFITS OF APQP TO DIRECT RESOURCES TO SATISFY CUSTOMER TO PROMOTE EARLY IDENTIFICATION OF REQUIRED CHANGES TO AVOID LATE CHANGES TO PROVIDE A QUALITY PRODUCT ON TIME AT LOWEST COST

1) DEFINE THE SCOPE 1.1 1.2 1.3 1.4 1.5 1.6 TEAM TO TEAM TRAINING CUSTOMER AND SUPPLIER INVOLVEMENT SIMULTANEOUS ENGINEERING CONTROL PLANS CONCERN SOLUTION

: ESTABILISHING COMMUNICATION BET

: CROSS FUNCTIONAL TEAM(MULTI-DIS

: CONCERNS IN PRODUCT AND PROCE

2) PLAN AND DEFINE PROGRAM

PRODUCT QUALITY PLANNI

CONCEPT INITIATION/APPROVAL

PROGRAM APPR

PLANNING

PRODUCT DESIGN A

PRO

FE

PLAN AND DEFINE PROGRAM

PLAN AND DEFINE PROGRAM

INPUTS 2.1 VOICE OF THE CUSTOMER : MARKET REASEARCH: HISTORICAL WARRANTY AND QUALITY INFORMATION: TEAM EXPERIENCE 2.2 BUSINESS PLAN/ MARKETING STRATEGY 2.3 PRODUCT/PROCESS BENCHMARK DATA 2.4 PRODUCT/PROCESS ASSUMPTION 2.5 PRODUCT RELIABILITY STUDIES 2.6 CUSTOMER INPUTS OUTPUTS 2.1 DESIGN GOALS 2.2 RELIABILITY AND QUALITY GOALS 2.3 PRELIMINARY BILL OF MATERIALS 2.4 PRELIMINARY PROCESS FLOW CHART 2.5 PRELIMINARY LISTING OF SPECIAL PRODUCT AND PROCESS CHARACTERISTICS 2.6 PRODUCT ASSURANCE PLAN 2.7 MANAGEMENT SUPPORT * NOTE : OUTPUT FOR EVERY STAGE BECOMES INPUT FOR NEXT STAGE 3) PRODUCT DESIGN AND DEVELOPMENT INPUTS 3.1 3.2 3.3 3.4 3.5 3.6 3.7

DESIGN GOALS RELIABILITY AND QUALITY GOALS PRELIMINARY BILL OF MATERIALS PRELIMINARY PROCESS FLOW CHART PRELIMINARY LISTING OF SPECIAL PRODUCT AND PROCESS CHARACTERISTICS PRODUCT ASSURANCE PLAN MANAGEMENT SUPPORT

OUTPUTS BY DESIGN RESPONSIBLE ACTIVITY 3.1 DESIGN FAILURE MODE AND EFFECT ANALYSIS 3.2 DESIGN FOR MANUFACTURABILTY AND ASSEMBLY 3.3 DESIGN VERIFICATION 3.4 DESIGN REVIEWS 3.5 PROTOTYPE BUILD- CONTROL PLAN 3.6 ENGINEERING DRAWINGS 3.7 ENGINEERING SPECIFICATIONS 3.8 MATERIAL SPECIFICATIONS 3.9 DRAWING AND SPECIFICATION CHANGES 3.1 NEW EQUIPMENT,TOOLING AND FACILITIES REQUIRED 3.11 SPECIAL PRODUCT AND PROCESS CHARACTERISTICS 3.12 GAUGES/TESTING EQUIPMENTS REQUIREMENTS 3.13 TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT

4) PROCESS DESIGN AND DEVELOPMENT INPUTS 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.1 4.11 4.12 4.13

DESIGN FAILURE MODE AND EFFECT ANALYSIS DESIGN FOR MANUFACTURABILTY AND ASSEMBLY DESIGN VERIFICATION DESIGN REVIEWS PROTOTYPE BUILD- CONTROL PLAN ENGINEERING DRAWINGS ENGINEERING SPECIFICATIONS MATERIAL SPECIFICATIONS DRAWING AND SPECIFICATION CHANGES NEW EQUIPMENT,TOOLING AND FACILITIES REQUIRED SPECIAL PRODUCT AND PROCESS CHARACTERISTICS GAUGES/TESTING EQUIPMENTS REQUIREMENTS TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT

OUTPUTS 4.1 PACKAGING STANDARDS 4.2 PRODUCT/PROCESS QUALITY SYSTEM REVIEW 4.3 PROCESS FLOW CHART 4.4 FLOOR PLAN LAYOUT 4.5 CHARACTERISTICS MATRIX 4.6 PROCESS FALIURE MODE AND EFFECT ANALYSIS 4.7 PRE-LAUNCH CONTROL PLAN 4.8 PROCESS INSTRUCTIONS 4.9 MEASUREMENT SYSTEM ANALYSIS PLAN 4.1 PRELIMINARY PROCESS CAPABILITY STUDY PLAN 4.11 PACKAGING SPECIFICATIONS 4.12 MANAGEMENT SUPPORT 5) PRODUCT AND PROCESS VALIDATION INPUTS 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.1 5.11 5.12

PACKAGING STANDARDS PRODUCT/PROCESS QUALITY SYSTEM REVIEW PROCESS FLOW CHART FLOOR PLAN LAYOUT CHARACTERISTICS MATRIX PROCESS FALIURE MODE AND EFFECT ANALYSIS PRE-LAUNCH CONTROL PLAN PROCESS INSTRUCTIONS MEASUREMENT SYSTEM ANALYSIS PLAN PRELIMINARY PROCESS CAPABILITY STUDY PLAN PACKAGING SPECIFICATIONS MANAGEMENT SUPPORT

OUTPUTS 5.1 PRODUCTION TRIAL RUN 5.2 MEASUREMENT SYSTEMS EVALUATION 5.3 PRELIMINARY PROCESS CAPABILITY STUDY

5.4 5.5 5.6 5.7 5.8

PRODUCTION PART APPROVAL PRODUCTION VALIDATION TESTING PACKAGING EVALUATION PRODUCTION CONTROL PLAN QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT

6) FEEDBACK ASSESSMENT AND CORRECTIVE ACTION INPUTS 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

PRODUCTION TRIAL RUN MEASUREMENT SYSTEMS EVALUATION PRELIMINARY PROCESS CAPABILITY STUDY PRODUCTION PART APPROVAL PRODUCTION VALIDATION TESTING PACKAGING EVALUATION PRODUCTION CONTROL PLAN QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT

OUTPUTS 6.1 REDUCED VARIATION 6.2 CUSTOMER SATISFACTION 6.3 DELIVERY AND SERVICE 7) CONTROL PLAN METHODOLOGY

``

*DESIGN RESPONSIBLE DEFINE THE SCOPE PLAN AND DEFINE PROGRAM PRODUCT DESIGN AND DEVELOPMENT FEASIBILITY PROCESS DESIGN AND DEVELOPMENT PRODUCT AND PROCESS VALIDATION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION CONTROL PLAN METHODOLOGY X X X X X X X X

THE PRODUCT ASSURANCEPLAN TRANSLATES DESIGN GOALS INTO DESIGN REQUIREMENTS.

THE PRODUCT ASSURANCE PLAN CAN BE BE DEVELOPED IN ANY UNDERSTANDABLE FORMAT AND SHO 1. OUTLINING OF PROGRAM REQUIREMENTS

2.IDENTIFICATION OF RELIABILITY, DURABILITY, AND APPORTIONMENT/ALLOCATION GOALS AND/OR RE

3. ASSESSMENT OF NEW TECHNOLOGY, COMPLEXITY, MATERIALS,APPLICATION,ENVIRONMENT,PACKA 4.DEVELOPMENT OF FAILURE MODE ANALYSIS 5. DEVELOPMENT OF PRELIMINARY ENGINEERING STANDARDS REQUIREMENTS. THE PRODUCT ASSURANCE PLAN IS AN IMPORTANT PART OF PRODUCT QUALITY PLAN

E PRODUCT QUALITY PLANNING (APQP)

: ESTABILISHING COMMUNICATION BETWEEN CUSTOMER AND SUPPLIER TO RESOLVE VARIOUS ISSUES

: CROSS FUNCTIONAL TEAM(MULTI-DISCIPLINARY TEAM) FROM VARIOUS DEPARTMENT STRIVES FOR COMMON GOAL : CONCERNS IN PRODUCT AND PROCESS TO BE DOCUMENTED ON A MATRIX

PRODUCT QUALITY PLANNING TIMING CHART

PROGRAM APPROVAL

PROTOTYPE

PILOT

PRODUCT DESIGN AND DEVELOPMENT PROCESS DESIGN AND DEVELOPMENT PRODUCT AND PROCESS VALIDATION

FEEDBACK ASSESMENT AND CORRECTIVE ACTION

PRODUCT DESIGN AND DEVELOPMENT VERIFICATION

PROCESS DESIGN AND DEVELOPMENT VERIFICATION

PRODUCT DESIGN AND DEVELOPMENT VERIFICATION

PROCESS DESIGN AND DEVELOPMENT VERIFICATION

ORMATION:

ROCESS CHARACTERISTICS

ROCESS CHARACTERISTICS

PRODUCT QUALITY PLANNING RESPONSIBILITY MATRIX

*DESIGN RESPONSIBLE X X X X X X X X

*MANUFACTURING ONLY X

X X X X X X

PRODUCT ASSURANCE PLAN INTO DESIGN REQUIREMENTS.

NY UNDERSTANDABLE FORMAT AND SHOULD INCLUDE, BUT IS NOT LIMITED TO FOLLOWING ACTIONS

NMENT/ALLOCATION GOALS AND/OR REQUIREMENT

ALS,APPLICATION,ENVIRONMENT,PACKAGING,SERVICE, AND MANUFACTURING REQUIREMENTS, OR ANY OTHER FACTOR THA

REQUIREMENTS.

RODUCT QUALITY PLAN

S FOR COMMON GOAL

PILOT

LAUNCH

PLANNING

N PRODUCTION

PRODUCT AND PROCESS VALIDATION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

PRODUCT AND PROCESS VALIDATION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

*SERVICE SUPPLIER I.E HEAT TREATMENT,WAREHOUSING,TRANSPORTATION ETC. X

X X X X X X

OR ANY OTHER FACTOR THAT MAY PLACE THE PROGRAM AT RISK

PRODUCT QUALITY PLANNING CHECKLISTS

A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8

DESIGN FMEA CHECKLIST DESIGN INFORMATION CHECKLIST NEW EQUIPMENT TOOLING AND TEST EQUIPMENT CHEKLIST PRODUCT/PROCESS QUALITY CHECKLIST FLOOR PLAN CHECK LIST PROCESS FLOW CHART CHECKLIST PROCESS FMEA CHECKLIST CONTROL PLAN CHECKLIST

A-1 DESIGN FMEA CHECKLIST CUSTOMER OR INTERNAL PART NO: QUESTIONS 1. WAS THE SFMEA OR DFMEA PREPARED USING CHRYSLER AND GENERAL MOTORS Pfmea REFERNCE MANUAL 2. HAVE HISTORICAL CAMPAIGN AND WARRANTY DATA BEEN REVIEWED 3. HAVE SIMILAR PART DFMEAs BEEN CONSIDERED 4.DOES SFMEA AND / OR DFMEA IDENTIFY SPECIAL CHARACTERISTICS 5.HAVE DESIGN CHARACTERISTICS THAT AFFECT HIGH RISK PRIORITY FAILURE MODES BEEN IDENTIFIED 6.HAVE APPROPRIATE CORRECTIVE ACTIONS BEEN ASSIGNED TO HIGH RISK PRIORITY NUMBERS 7.HAVE APPROPRIATE CORRECTIVE ACTIONS BEEN ASSIGNED TO HIGH SEVERITY PRIORITY NUMBERS 8. HAVE RISK PRIORITIES BENN REVISED WHEN CORRECTIVE ACTIONS HAVE BEEN COMPLETED AND VERIFIED

NING CHECKLISTS

ND TEST EQUIPMENT CHEKLIST Y CHECKLIST

YES

NO

COMMENT/ACTIONREQUIRED

PERSON RESPONSIBLE

ORITY NUMBERS

Y PRIORITY NUMBERS

EN COMPLETED

PERSON RESPONSIBLE

DUE DATE

APQP (BRIEF) BENEFITS OF APQP:TO DIRECT RESOURCES TO SATISFY CUSTOMER TO PROMOTE EARLY IDENTIFICATION OF REQUIRED CHANGES TO AVOID LATE CHANGES TO PROVIDE A QUALITY PRODUCT ON TIME AT LOWEST COST 5 STAGES:1) PLAN AND DEFINE PROGRAM I/P (input) VOICE OF CUSTOMER PRODUCT RELIABILITY STUDIES CUSTOMER REJECTION&COMPLAINTS PRODUCT/PROCESS BENCHMARK DATA PRODUCT/PROCESS ASSUMPTIONS O/P (output) RELIABILTY AND QUALITY GOALS PRELIMINARY BOM PRELIMINARYPROCESS FLOW CHART PRODUCT ASSURANCE PLAN PRELIMINARY LISTING: SC's AND CC's 2) PRODUCT DESIGN AND DEVELOPMENT I/P I/P

3) PROCESS DESIGN

O/P DFMEA FEASIBILITY SC's AND CC's NEW PATTERN AND CORE BOXES GAUGES AND TESTING DESIGN REVIEW AND VERIFICATION ENGG. DRG. AND SPECFICATIONS DRG. AND SPECIFICATIONS. CHANGES O/P

PFMEA PFD(PROCESS FLOW MSA CONTROL PLAN PROCESS CAPABILIT PACKAGING STANDA

3) PROCESS DESIGN AND DEVELOPMENT

4) PRODUCT AND PROCESS VALIDATION I/P I/P

5) FEEDBACK ASSESSMENT AND C

O/P PFD(PROCESS FLOW DIAGRAM) CONTROL PLAN PROCESS CAPABILITY STUDY PLAN PACKAGING STANDARDS PPAP MSA EVALUATION PRODUCTION CONTROL PLAN PROCESS CAPABILITY STUDY PRODUCTION VALIDATION TESTING

O/P CUSTOMER SATISFACTION DELIVERY AND SERVICE REDUCED VARIATION

DBACK ASSESSMENT AND CORRECTIVE ACTION

TOMER SATISFACTION VERY AND SERVICE UCED VARIATION