7.2.4 APQP Phase 1 Checklist Dec 2013

User Guide
# Question Y* N N/A RYG

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
X 25%
N/A
IP 50%
Status (%):
25% - Action Identified 50% - Owner Identified
75% - Action in Progress 100% - Action Closed
75% R
100% Y
G Green: All questions have a positive answer (Y) and are ongoing
normal program development
Deliverable RYG Rating
Red: Some questions have a negative answer and no recovery
plan is in place or the plans identified will have an impact in
program timing. Support is required. When an item is highlighted
Red an assessment on the impact to the WP timing needs to be
Yellow: Some questions have a negative answer but a recovery
plan is in place which will prevent impact on timing
Evidence
The questions are used to evaluate the
quality of the deliverable attached to the
element.
Typical aspects of the deliverable to be
evaluated through the questions are:
1. Quality/availability of the inputs needed
to build the deliverable
2. Cross-functional approach to answer the
deliverables
3. Quality /conformity to a standard if any
or to best practices
4. control of the outcome of the deliverable
(e.g. action plan)

Input evidence of the answer to the
question (e.g.: document reference) here.
If an "X" is in the preceding N column
(column D) then describe the issue here
including root cause in order to identify
proper actions .
Y* - Put an "X" if complete and is OK or "IP"
if in-progress as planned.
N - Put an "X" if it is Not OK .
N/A - Put an "X" if you have agreed with
your customer that this question is Not
Applicable.
RYG - Put an "R" here if the answer to the
question is not acceptable and there is no
recovery plan. Put a "Y" here if there are
problems with the question but is
recoverable with an action plan inplace.
Put a "G" if it is on track or satisfactorily
complete. When you put an "R" or "Y" you
will need to complete the "Actions
Required" and subsequent columns.

User Guide
# Question
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
X
IP
Status (%):
The questions are used to evaluate the
quality of the deliverable attached to the
element.
Typical aspects of the deliverable to be
evaluated through the questions are:
1. Quality/availability of the inputs needed
to build the deliverable
2. Cross-functional approach to answer the
deliverables
3. Quality /conformity to a standard if any
or to best practices
4. control of the outcome of the deliverable
(e.g. action plan)

Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
Actions Required Responsible
Actions identified based on the
root cause described in the
Evidence column when the RYG
column is Red or Yellow.
These are typical action management milestones .
The due date should be aligned with the closure date
of the deliverable as planned in the APQP timing. In
cases where the due date is not aligned with APQP
timing, the RYG status is most likely Red .
Date of
revision for
the provided
status and
1.01 Project Inputs
1
Was a a cross-functional team used to gather project
inputs including the following as applicable: Program
Management, Quality, Design Engineering,
Manufacturing Engineering, Marketing and Sales,
Procurement?
2
Are applicable regulatory requirements available?
3
Are customer requirements available including:
Project milestones and product delivery date
Projected volumes
Project lifecycle
Product and process assumptions
4
Are all internal data to build product performance
expectations available including:
Historical problems internal and external
Warranty
Reliability requirements
Quality requirements
Technical Requriements
5
Have lesson learned been conducted including:
Best Practices
Project management
Quality issues
Product design guidelines
Process design guidelines
6
Is the company strategy available including:
Business plan
Marketing strategy
Industrial strategy
Technical strategy
7
Have the resulting project/product requirements been
referenced/recorded into a repository, including
supporting data?
Data is made available to be used by the project
team?
8
Is there a process to keep formal requirements
document up-to-date?
9
Has (Have) any potential risk(s) not highlighted by
previous question been identified? If no, describe this
risks?
10
11
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G
Red: Some questions have a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is required. When an item is
highlighted Red an assessment on the impact to the WP timing needs to be provided.
Yellow: Some questions have a negative answer but a recovery plan is in place which will
prevent impact on timing
Green: All questions have a positive answer (Y) and are ongoing normal program
development
Evidence
1.01 Project Inputs
# Question Y* N N/A RYG Evidence
1.01 Project Inputs
# Question
1
Was a a cross-functional team used to gather project
inputs including the following as applicable: Program
Management, Quality, Design Engineering,
Manufacturing Engineering, Marketing and Sales,
Procurement?
2
Are applicable regulatory requirements available?
3
Are customer requirements available including:
Project milestones and product delivery date
Projected volumes
Project lifecycle
Product and process assumptions
4
Are all internal data to build product performance
expectations available including:
Historical problems internal and external
Warranty
Reliability requirements
Quality requirements
Technical Requriements
5
Have lesson learned been conducted including:
Best Practices
Project management
Quality issues
Product design guidelines
Process design guidelines
6
Is the company strategy available including:
Business plan
Marketing strategy
Industrial strategy
Technical strategy
7
Have the resulting project/product requirements been
referenced/recorded into a repository, including
supporting data?
Data is made available to be used by the project
team?
8
Is there a process to keep formal requirements
document up-to-date?
9
risks?
10
11
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.01 Project Inputs
# Question
Open
Date
Due
Date
Status
%
Actual End
Date Actions Required Responsible
1.02 Technical Design Requirements
1
Have all project inputs (lessons learned,
strategies,customer needs, product performance)
been taken into account when defining the
requirements?
2
Has the requirements set been built by a cross
functional team involving engineering, sales,
manufacturing engineering, procurement, quality and
production?
3
Are all requirements traceable (identifier, author,
rationale, source, requirement owner, allocation and
stakeholder)?
4
Has the requirements set been validated and
approved by identified personnel?
5
Are requirements recorded into the program
applicable database?
6
Are all design and product verifications planned and
their respective evidence managed in a database?
7
Have allocated requirements been understood and
accepted by all the recipients?
8
Is there is a robust requirements change
management process in place?
9
risks?
10
11
12
13
14
15
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G Green: All questions have a positive answer (Y) and are ongoing normal program
development
Evidence
1.02 Technical Design Requirements
# Question
1
Have all project inputs (lessons learned,
strategies,customer needs, product performance)
been taken into account when defining the
requirements?
2
Has the requirements set been built by a cross
functional team involving engineering, sales,
manufacturing engineering, procurement, quality and
production?
3
Are all requirements traceable (identifier, author,
rationale, source, requirement owner, allocation and
stakeholder)?
4
Has the requirements set been validated and
approved by identified personnel?
5
Are requirements recorded into the program
applicable database?
6
Are all design and product verifications planned and
their respective evidence managed in a database?
7
Have allocated requirements been understood and
accepted by all the recipients?
8
Is there is a robust requirements change
management process in place?
9
risks?
10
11
12
13
14
15
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.03 Reliability and Quality Goals
1
Were the quality and reliability goals created by a
cross functional team including members from
quality,design engineering, manufacturing
engineering, customer support, reliability
engineer)?
2
Are there quality goals covering the product lifecycle
(concept, design, production and service)?
3
Are reliability goals covering all project aspects
(product lifetime, Operational Reliability, Repairs and
breakdowns (e.g.:MTBR, MTBUR,MTBF),
performance stability, performance forecast)?
4
Are quality and reliability goals covering Customer
requirements, Regulatory and internal operations
requirements?
5
Are quality and reliability goals consistent with
overall company , customer and program objectives?
6
Are quality and reliability goals SMART (Specific,
Measurable, Achievable, Reachable yet Challenging
and Timebound)?
7
Does each goal have an accountable leader and
commitment obtained ?
8
Are metrics and targets effectively communicated
and cascaded?
9
Do metrics and targets drive specific action plans
towards continuous improvement?
10
Have all potential risks affecting the element been
identified?
11
12
13
14
15
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
development
Evidence
1.03 Reliability and Quality Goals
# Question
1
Were the quality and reliability goals created by a
cross functional team including members from
quality,design engineering, manufacturing
engineering, customer support, reliability
engineer)?
2
Are there quality goals covering the product lifecycle
(concept, design, production and service)?
3
Are reliability goals covering all project aspects
(product lifetime, Operational Reliability, Repairs and
breakdowns (e.g.:MTBR, MTBUR,MTBF),
performance stability, performance forecast)?
4
Are quality and reliability goals covering Customer
requirements, Regulatory and internal operations
requirements?
5
Are quality and reliability goals consistent with
overall company , customer and program objectives?
6
Are quality and reliability goals SMART (Specific,
Measurable, Achievable, Reachable yet Challenging
and Timebound)?
7
Does each goal have an accountable leader and
commitment obtained ?
8
Are metrics and targets effectively communicated
and cascaded?
9
Do metrics and targets drive specific action plans
towards continuous improvement?
10
identified?
11
12
13
14
15
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.04 Preliminary Listing of Critical Items (CTIs) and Key Characteristics (KCs)
1
Has a Cross functional team been set and led by
Design engineering reponsible for all considered
products. Team includes representatives from all of
the key involved domains (Quality, Manufacturing
engineering, production, )?
2
Is there a method in place to determine CTI and KC
in line with the aplicable international norm 9103?
3
Are necessary inputs identified including: product
performance requirements (eg. interchangeability),
product risk analysis on similar products,
manufacturing requirements, existing data on
manufacturing process performance, failures and
their resolution at customers and throughout product
lifecycle?
4
Can identified CTI/KC be justified?
CTI/KC come from experience or are determined
using clear methodologies such as Quality Function
Deployment Matrices.
5
Is the preliminary listing signed off by all of the team
members?
Suggested - written evidence of the agreement
6
Has this list been communicated to the activities
downstream to continue with the CTI / KC cascade?
It is recommended that this list is incorporated into
the product specification and process specification.
7
risks?
8
9
10
11
12
13
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
development
Evidence
1.04 Preliminary Listing of Critical Items (CTIs) and Key Characteristics (KCs)
# Question
1
Has a Cross functional team been set and led by
Design engineering reponsible for all considered
products. Team includes representatives from all of
the key involved domains (Quality, Manufacturing
engineering, production, )?
2
Is there a method in place to determine CTI and KC
in line with the aplicable international norm 9103?
3
Are necessary inputs identified including: product
performance requirements (eg. interchangeability),
product risk analysis on similar products,
manufacturing requirements, existing data on
manufacturing process performance, failures and
their resolution at customers and throughout product
lifecycle?
4
Can identified CTI/KC be justified?
CTI/KC come from experience or are determined
using clear methodologies such as Quality Function
Deployment Matrices.
5
Is the preliminary listing signed off by all of the team
members?
Suggested - written evidence of the agreement
6
Has this list been communicated to the activities
downstream to continue with the CTI / KC cascade?
It is recommended that this list is incorporated into
the product specification and process specification.
7
risks?
8
9
10
11
12
13
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.05 Manufacturer Product Specification
1
Are all necessary input documents available and
released (Design technical requirement documents,
Quality and reliability goals, process constraints)?
2
Are all requirements from input documents
cascaded into the product specification, traced and
recorded?
3
Has the design team verified that product
specification requirements are addressing the right
level of the system breakdown.(e.g.: do not require a
component supplier to meet an Aircraft level
requirement or impose an equipement specification
4
Is each requirement validated? Has the means of
validating each requirement been defined?
In case of no agreement on the requirement with
customer impacts are measured and actions
described accordingly.
5
Have the proof-reading and review process been
successfully completed? (internal by supplier and
with customer)?
6
Are CI/KC properly integrated into product
specification?
7
Is there consistency with other contractual
requirement documents (e.g.: SOW)?
8
Are there any changes foreseen (Change requests...)
which could impact product development agreed
schedules? Is there a mitigation action plan to
guarantee that the agreed schedule is met?
9
risks?
10
11
12
13
14
15
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G
Evidence
development
1.05 Manufacturer Product Specification
# Question
1
Are all necessary input documents available and
released (Design technical requirement documents,
Quality and reliability goals, process constraints)?
2
Are all requirements from input documents
cascaded into the product specification, traced and
recorded?
3
Has the design team verified that product
specification requirements are addressing the right
level of the system breakdown.(e.g.: do not require a
component supplier to meet an Aircraft level
requirement or impose an equipement specification
4
Is each requirement validated? Has the means of
validating each requirement been defined?
In case of no agreement on the requirement with
customer impacts are measured and actions
described accordingly.
5
Have the proof-reading and review process been
successfully completed? (internal by supplier and
with customer)?
6
Are CI/KC properly integrated into product
specification?
7
Is there consistency with other contractual
requirement documents (e.g.: SOW)?
8
Are there any changes foreseen (Change requests...)
which could impact product development agreed
schedules? Is there a mitigation action plan to
guarantee that the agreed schedule is met?
9
risks?
10
11
12
13
14
15
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.06 Bill of Material (BOM)
1 Are the technical/process requirements available?
2
Is the production startegy considered into
establishing the preliminary BOM/Product Break
down Structure?
3
Have benchmarks been conducted on similar and
competitor products?
4
Have cost targets been taken into account to
establish the PBS?
5
Have enviromental/regulatory requirements been
considered when establishing the preliminary
BOM/PBS?
6
Has the Bill Of Material been reviewed with
procurement, in order to integrate opportinities from
supply chain innovation or risks from it?
7
Has the preliminary Bill Of Material been agreed by
all project stakeholders (Engineering, manufacturing
engineering, procurement, Production)?
8
risks?
9
10
11
12
13
14
15
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G
Evidence
development
1.06 Bill of Material (BOM)
# Question
1 Are the technical/process requirements available?
2
Is the production startegy considered into
establishing the preliminary BOM/Product Break
down Structure?
3
Have benchmarks been conducted on similar and
competitor products?
4
Have cost targets been taken into account to
establish the PBS?
5
Have enviromental/regulatory requirements been
considered when establishing the preliminary
BOM/PBS?
6
Has the Bill Of Material been reviewed with
procurement, in order to integrate opportinities from
supply chain innovation or risks from it?
7
Has the preliminary Bill Of Material been agreed by
all project stakeholders (Engineering, manufacturing
engineering, procurement, Production)?
8
risks?
9
10
11
12
13
14
15
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.07 Preliminary Process Flow Chart
1
Was the manufacturing process flow chart created
by a cross functional team including Manufacturing
Engineering, Production and Quality (including others
as applicable)?
2
Is enough information available to create the process
flow chart?
All input data to the manufacturing flow chart are
avaiblable such as: preliminary design drawings,
preliminary bill of material, process
specificatioin/requirements, Preliminary Key
Characteristics and Critical Items, material/
components introduction points..
3
Is the process flow chart applicable to the product in
question?
At this stage generic process flow can be used .
4
Does the manufacturing flow chart include
manufacturing, inspection and test phases for
subassemblies and finished product?
The manufacturing process flow chart is not limited
to final assembly, it combines final assembly and
construction of all the subasseblies required to make
the product.
5
subcontracted activities?
The manufacturing process flow requirement is
cascaded to them.
6
Does the manufacturing flow chart include critical
process steps (e.g.: long lead time equipement,
processes requiring operators to be certified by
external parties)?
7
Does the process flow chart include Preliminary Key
Characteristics and their monitoring?
8
Does the process flow chart include means
(machine, equipment) & tools used? In so far as they
are identified.
9
Is the process flow chart kept up-to-date and
configuration managed?
10
identified?
11
12
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G
Evidence
development
1.07 Preliminary Process Flow Chart
# Question
1
Was the manufacturing process flow chart created
by a cross functional team including Manufacturing
Engineering, Production and Quality (including others
as applicable)?
2
Is enough information available to create the process
flow chart?
All input data to the manufacturing flow chart are
avaiblable such as: preliminary design drawings,
preliminary bill of material, process
specificatioin/requirements, Preliminary Key
Characteristics and Critical Items, material/
components introduction points..
3
Is the process flow chart applicable to the product in
question?
At this stage generic process flow can be used .
4
manufacturing, inspection and test phases for
subassemblies and finished product?
The manufacturing process flow chart is not limited
to final assembly, it combines final assembly and
construction of all the subasseblies required to make
the product.
5
subcontracted activities?
The manufacturing process flow requirement is
cascaded to them.
6
Does the manufacturing flow chart include critical
process steps (e.g.: long lead time equipement,
processes requiring operators to be certified by
external parties)?
7
Does the process flow chart include Preliminary Key
Characteristics and their monitoring?
8
Does the process flow chart include means
(machine, equipment) & tools used? In so far as they
are identified.
9
Is the process flow chart kept up-to-date and
configuration managed?
10
identified?
11
12
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.08 Statement of Work (SOW)
1
Is the Statement Of Work specific to the product?
Each of the requirements written in the SOW are
unique to the product, it is not a generic document
which refers to standard requirements.
2
Are all deliverables and inputs from the customer
listed, with expected maturity (e.g. draft, final), due
date and contributor (internal - external)?
3
Are assumptions, constraints and top the risks
identified in the SOW?
4
Is program timing for the product complete and
identified in the SOW and complete?
5
Are all applicable standards and procedures
identified int the SOW?
6
Are all technical/process requirements referenced int
the SOW?
The SOW describes the non technical requirements
and makes reference to the technical ones (see
element 1.02 and 1.05).
7
Are logistics requirements identified in the SOW?
8
Are quality and reliability targets identified in the
SOW?
9
Has the Statement Of Work covering all tasks been
formally approved by all affected functions and team
members and under change control?
10
risks?
11
12
13
14
15
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G
Evidence
development
1.08 Statement of Work (SOW)
# Question
1
Is the Statement Of Work specific to the product?
Each of the requirements written in the SOW are
unique to the product, it is not a generic document
which refers to standard requirements.
2
Are all deliverables and inputs from the customer
listed, with expected maturity (e.g. draft, final), due
date and contributor (internal - external)?
3
Are assumptions, constraints and top the risks
identified in the SOW?
4
Is program timing for the product complete and
identified in the SOW and complete?
5
Are all applicable standards and procedures
identified int the SOW?
6
Are all technical/process requirements referenced int
the SOW?
The SOW describes the non technical requirements
and makes reference to the technical ones (see
element 1.02 and 1.05).
7
Are logistics requirements identified in the SOW?
8
Are quality and reliability targets identified in the
SOW?
9
Has the Statement Of Work covering all tasks been
formally approved by all affected functions and team
members and under change control?
10
risks?
11
12
13
14
15
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.09 Sub-tier Selection and Management Plan
1
Does the Make/Buy decision process cover the full
scope of the Product Breakdown and statement of
work?
2
Does the make/buy decision incorprate the
production startegy and supply chain capability
analysis?
3
Does the supplier selection process involve key
functions (quality, engineering, procurement and
logistics) and balance the decision between all
parties?
Supplier performance is a key input to selection
process
4
Are all selected suppliers on the Approved Supplier
List/Preferred Supplier List and if not specific actions
are launched to make sure the supplier will meet
customer expectations?
5
Is there a plan (schedule and activies) for supplier
sourcing in place and aligned with program timing
needs?
6
Are the results of the selection for each item
formalized, including action decided during sourcing?
7
Is the list of requirements and objectives to be
cascaded to suppliers validated by all involved
parties and formalized?
8
Is there a process in place to monitor the supplier
performance compared to the cascaded objectives
(quality and delivery objectives)?
9
Can the supplier demonstrate that this cascade is
complete?
10
Is there a specific process to monitor subtier during
the industrailization phase and a dedicated
organization/infrastructure driven by program to
manage them?
11
risks?
12
13
14
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G
Evidence
development
1.09 Sub-tier Selection and Management Plan
# Question
1
Does the Make/Buy decision process cover the full
scope of the Product Breakdown and statement of
work?
2
Does the make/buy decision incorprate the
production startegy and supply chain capability
analysis?
3
Does the supplier selection process involve key
functions (quality, engineering, procurement and
logistics) and balance the decision between all
parties?
Supplier performance is a key input to selection
process
4
Are all selected suppliers on the Approved Supplier
List/Preferred Supplier List and if not specific actions
are launched to make sure the supplier will meet
customer expectations?
5
Is there a plan (schedule and activies) for supplier
sourcing in place and aligned with program timing
needs?
6
Are the results of the selection for each item
formalized, including action decided during sourcing?
7
Is the list of requirements and objectives to be
cascaded to suppliers validated by all involved
parties and formalized?
8
Is there a process in place to monitor the supplier
performance compared to the cascaded objectives
(quality and delivery objectives)?
9
Can the supplier demonstrate that this cascade is
complete?
10
Is there a specific process to monitor subtier during
the industrailization phase and a dedicated
organization/infrastructure driven by program to
manage them?
11
risks?
12
13
14
X
IP
Status (%):
Open
Date
Due
Date
Status
%
Actual End
Date
Location: / Site:
Reviewed by:
Reviewed with:
Date :
1.10 APQP Timeline
1
Does a formal APQP planning process exist?
2
Was the timing plan created by a cross functional
team including members from all activitities involved
(e.g., Quality, Engineering, Project Management,
Manufacturing Engineering)?
3
Is there a clear definition for when the product must
be delivered?
4
Have key milestones been established, including
external and internal program reviews ?
5
Have the necessary APQP Elements been agreed
upon by the project team?
6
Is there a start and an end date for each APQP
activity?
7
Have all necessary Interdependencies / clashes been
identified and agreed upon with related customer /
supplier?
8
Have the critical path(s) identified and optimized in
the plan from both time and risk perspectives and in
line with the APQP time plan?
9
Has the APQP timeline been validated by the
Customer,and committed to by all team members, &
Suppliers?
10
risks?
11
12
13
14
15
X 25%
N/A
IP 50%
Status (%):
75% R
100% Y
G
Evidence
development
1.10 APQP Timeline
# Question
1
Does a formal APQP planning process exist?
2
Was the timing plan created by a cross functional
team including members from all activitities involved
(e.g., Quality, Engineering, Project Management,
Manufacturing Engineering)?
3
Is there a clear definition for when the product must
be delivered?
4
Have key milestones been established, including
external and internal program reviews ?
5
Have the necessary APQP Elements been agreed
upon by the project team?
6
Is there a start and an end date for each APQP
activity?
7
Have all necessary Interdependencies / clashes been
identified and agreed upon with related customer /
supplier?
8
Have the critical path(s) identified and optimized in
the plan from both time and risk perspectives and in
line with the APQP time plan?
9
Has the APQP timeline been validated by the
Customer,and committed to by all team members, &
Suppliers?
10
risks?
11
12
13
14
15
X
IP
Status (%):
Open
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7.2.4 APQP Phase 1 Checklist Dec 2013

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7.2.4 APQP Phase 1 Checklist Dec 2013

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