Supplier APQP: Four Phases Magna Electronics (MEI) - 4 Phases of APQP for Supplier Development Development Engineering APQP -> Phase 1
APQP -> Phase 2
APQP -> Phase 3
Supplier Kick-Off and Planning
Product/Process Realization
Pre-PPAP
APQP -> Phase 4 Product/Process Validation and Launch
Identify MEI and Supplier team contacts/roles/responsibilities
Create and/or review DFMEA as appropriate depending upon design resp.
Communicate an and in initiate Ke Key Su Supplier Me Metrics
Develop pr process fl flow ch chart (d (diagram).
Initial Supplier Program plan and timing
Create & review preliminary process flow diagram, PFMEA, and Control Plan.
Finalize PCM: prepare fo for Safe Launch
Launch Readiness Au Audit
Conduct Cross-functional component design review (doc is located in GSQM)
Finalize PCM & use document for any preproduct part runs.
Finalize PFMEA and Co Control Plan
Confirmation of of full vo volume Run-At-Rate
Create preliminary Product Characteristics Matrix (PCM) - Safe Launch Plan
Confirm tooling and gage construction progress.
Review Supplier Ramp Plan
Finalize component packaging review
Develop Process Process Instructions Instructions
Launch Readiness Readiness Audit: document key key metrics
Initiate Safe Launch practice & review supplier's data for appropriate actions.
Re-qualify equipment, equipment, tooling & gaging as it moves between supplier site(s)
Review Key Supplier Metrics
APQP Requirements Requirements
Pre-production run
Process ca capability st study
Equipment Tooling & gage concept/design review.
Finalize Process capability study
Review MEI PPAP Requirments with the supplier (per MEI PPAP Checklist)
Validation review of "1st Off" tool/part condition(s). Address any issues that can't be contained w/n program timing.
Appearance Approval (as (as appropriate) appropriate)
Review supplier's manufacturing feasibility document(s)
Floor plan layout
Supplier participates in Plant Readiness Review
Review preliminary capacity study & initial supplier master schedule plan
Update previous phase open issues and key documents
Review status of Key Supplier Metrics
Iniate Open Issues Document
Plan
Finalize complete PPAP submission package
Cross functional key metrics review: Launch sign off
Close-out previous phase open issues and key documents
Update previous phase open issues and key documents.
Component Criticality Rating A= MEI SDE will coduct APQP 1 - 4 w/ Supplier B= MEI SDE will conduct APQP 1 and 4 w/ Supplier. PPAP only to SDE. Supplier is still responsible for C= maintaining APQP 1-4.
Date: 14 May, 2008 Rev. A
Magna Electronics Electronics APQP Woorkbook
Process Owner/Department: Chris Hempsall Approved by: by: Justin Reaume / Pur Dir
Supplier APQP: Table of Contents Cover
Shows the 4 APQP Phases and the activities that occur within them.
Table of Contents
Lists all of the forms and examples included in this workbook. The Worksheet with "Tabs" highlighted in YELLOW require supplier documentation and reporting back to MEI SDE.
Supplier Feasibility Statement
In accordance with The Automotive Industry Action Group (AIAG) and OE specific requirements, the supplier's team feasibility commitment document initiates the MEI APQP process. Unless exceptions or concerns are communicated to MEI as part of the quoting process it is the ass umption that the supplier will be providing product that is fully compliant to all applicable drawings and specifications.
Blank Time Line
Suppliers are required to create a Master Time Line for the launch of the awarded component(s). It is expected that a Gantt chart is used as the format. For those suppliers who do not not have software available to meet this this requirement, a blank time line is provided for their use.
Key Metrics Definitions
Operational definitions definitions for the twelve key metrics. Explains the metric and its method of calculation. calculation.
Key Metrics Report
Key Metrics contain those elements that that contribute to a successful launch. This form allows for four reviews. reviews. The minimum requirement is to use the first two columns at APQP-2 and APQP-4. The APQP-3 report is generated during the first parts off run at the supplier's manufacturing manufacturing location. This establishes a baseline performance performance on the process in its "as received" state. The APQP-4 report is generated generated at the the time product is manufactured manufactured for the PPAP submission. The additional columns would either be used at the discretion of the SDE or based on circumstances that require additional reviews.
Supply Chain Map Example
An example of how how a Supply Chain Map may appear for for a typical metal component. component.
Supply Chain Map
Form for showing multi-tier supply chain relationships involved in providing the component/assembly to MEI. The information documented here will also be used in the creation of the Product Characteristics Matrix (PCM).
Product Characteristics Characteristics Matrix Tier II
The PCM is used initially to define and determine appropriate controls controls for special characteristics, other process critical features and customer touch points. points. This tab is used to define the process at MEI's MEI's direct supplier. Throughout the APQP phase of launch this form is used as the Pre-Launch Control Plan and also forms the basis for Safe Launch Planning.
Product
The use of this tab is identical to the functionality define above, with the exception that this is used to document the
Supplier Design Review Sign Off Part Name:
Part No.:
Date: ________________
Rev. No.: Review Considerations: ME and supplier product quality planning team has considered the following questions, not intended to be all-inclusive in performing a feasibility evaluation. The drawings and / or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All "no" answers are supported with attached comments identifying our concerns and proposed changes to enable us to meet the specified requirements.
YES
Considerations
NO
Is the product adequately defined (application requirements, etc.) to enable feasibility evaluation ? Can Engineering Performance Specifications be met as written? Can product be manufactured to tolerances specified on drawing? Can product be manufactured with Cpk's that meet requirements? Is there adequate capacity to produce product? Does the design allow the use of efficient material handling techniques? Can product be manufactured without incurring any unusual: l Costs for capital equipment? l Costs for tooling? l Alternative manufacturing methods? Is statistical process control required on product? Is statistical process control presently used on similar products? Where statistical process control is used on similar products: l Are the processes in control and stable? l Are Cpk's greater than 1.33? Is the appropriate packaging available to protect the product during shipment? (Provide a proposal)
Are special / uncom mon materials required tha t are not readily available ? Conclusion: Feasible Feasible (Conditional) Not Feasible Issue #
Open
Close
> Product can be produced as specified with no revisions. > Changes recommended (see issues list below). > Design revision required to produce product within the specified requirements.
Issues / Comments / Risks
Corrective Actions / Resolution Plan
Supplier APQP: Four Phase Time Line (EXAMPLE) The Magna Electronics Supplier Advanced Product Quality Planning (APQP) process consists of 4 Phases. Essential to this process are 12 Key Supplier Metrics (KSM). These metrics are established in the initial phase and then updated and reviewed during each of the following phases. The time line below ill ustrates the relationship between the 4 Phases, their deliverables and the Global Development & Product Introduction Management process. This workbook consists of 9 forms in support of this process (the respective tab colors are highlighted in "yellow"). Suppliers are expected to use this process regardless of the priority ranking assigned components/materials requiring submission of a PPAP package. P E Q S P A A H P f f O k c i . K 1 r e i l p p u S
Year 1 OUTPUT 1.1 1.2 1.3 1.4
1.5 1.6 1.7 2.1 2.2 n o i 2.3 t c n u o 2.4 d i t 2. 5 . o r a z 2 P l i / t a 2.6 c e u 2. 7 d R o 2.8 r P 2.9 2.10 3. 1 3.2 P 3.3 A 3.4 . P 3 P 3.5 e r P 3.6 3.7 3.8 & 4.1 / t s n c s o 4.2 . u e i t 4 d c a 4.3 o d o r r i 4.4 P P l a V 4.5 5.1 s t n 5.2 r e 5.3 . e m e 5.4 5 h t i r O u 5.5 q e 5.6 R 5.7
Year 2
2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 0 0 0 0 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 0 0 0 0 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5
Design FMEA Preliminary Capacity Study reviewed Manufacturing Feasibility reviewed Component Design Review Product Characteristic Matrix initiated Key Supplier Metrics initiated Supplier Project timing plan Open Issues Action Plan created Measurement/ Testing equipment Preliminary Process Flow Chart Review Preliminary PFMEA Review Preliminary Control Plan Review Tool ing Capital equipment Tr ai ni ng Process instructions Packaging Key Supplier Metrics reviewed ELV/I MD S Safe Launch Plan (PCM) finalized Sub-Supplier PPAP Approvals Supplier Ramp Plan Plant Readiness Review Launch Readiness Audit Appearance Approval Process (when applicable) Key Supplier Metrics reviewed PPAP Launch Readiness Audit Run at Rate Key Supplier Metrics reviewed OK to Launch Sign-Off
KEY:
X Planned start
O
Planned completion
Magna Electronics APQP Workbook
+
Actual start
>
Actual end
Supplier APQP: Blank Time Line P E Q S P A A H P f f O k c i . K 1 r e i l p p u S
Year 1 OUTPUT 1.1 1.2 1.3 1.4
1.5 1.6 1.7 2.1 2.2 n o i 2.3 t c n u o 2.4 d i t o a 2.5 . r z 2 P l / i 2.6 t c a e u R 2.7 d o 2.8 r P 2.9 2.10 3.1 3.2 P 3.3 A 3.4 . P P 3 3.5 e r P 3.6 3.7 3.8 4.1 / s & t n c s o 4.2 i . u e t 4 d c a 4.3 o d o r r i 4.4 P P l a V 4.5 5.1 s t n 5.2 e r 5.3 e m . h e 5.4 5 t r i O u 5.5 q e 5.6 R 5.7
Year 2
2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 0 0 0 0 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 0 0 0 0 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5
Design FMEA Preliminary Capacity Study reviewed Manufacturing Feasibility reviewed Component Design Review Product Characteristic Matrix initiated Key Supplier Metrics initiated Supplier Project timing plan Open Issues Action Plan created Measurement/ Testing equipment Preliminary Process Flow Chart Review Preliminary PFMEA Review Preliminary Control Plan Review Tool ing Capital equipment Tr ai ni ng Process instructions Packaging Key Supplier Metrics reviewed ELV/IMDS Safe Launch Plan (PCM) finalized Sub-Supplier PPAP Approvals Supplier Ramp Plan Plant Readiness Review Launch Readiness Audit Appearance Approval Process (when applicable) Key Supplier Metrics reviewed PPAP Launch Readiness Audit Run at Rate Key Supplier Metrics reviewed OK to Launch Sign-Off
KEY:
X Planned start
O
Planned completion
+
Actual start
>
Actual end
APQP: Key Supplier Metrics Operational Definitions This section define s the Key Supplier Metrics that will be tracked throughout the four APQP Phases. Reviews will be held toward the end of each of the four phases. Review of these metrics, in the Phase 4, will take place before the final full PPAP approval
Metric APQP Readiness
Definition
Goal
Data is derived from the 'APQP Progress Report'. This metric tracks the percentage of GREEN elements compared to the total number of elements being tracked.
Results Enter the number of GREEN elements at the time of the report.
Enter the total number of elements being tracked. There are 34 elements on the APQP Progress Report. For suppliers where the DFMEA does not apply subtract 1. For suppliers who are not providing an Appearance item, subtract 1.
Process Instructions
Total number of set-up, manufacturing and inspection instructions needed.
Enter number of completed process instructions at the time of the review. Enter total number of process instructions needed for serial production.
First time Capability
Percentage of good parts to the total number of parts produced during the Run at Rate.
Enter, as a decimal number, the ratio of total parts produced to good parts from the trial run. Enter the number '1,' which represents the production of 100% good, or usable, parts.
Process Efficiency
Measured in available capacity. Expectation for open capacity is 15% minimum. This is achieved by dividing Takt time into cycle time and subtracting the result from 1.
The amount of available capacity at the time of the review. Enter result as a decimal number. The minimum amount of available capacity should be 15% (85% utilization). Enter 0.15
APQP: Key Supplier Metrics Operational Definitions This section defines the Key Supplier Metrics that will be tracked throughout the four APQP Phases. Reviews will be held toward the end of each of the four phases. Review of these metrics, in the Phase 4, will take place before the final full PPAP approval
Metric
Definition
Goal
Process Implementation - This metric assesses the level of % Completed implementation of the full production intent process. Processes that are not fully implemented at the Start-ofProduction require a deviation, or concession, to allow shipment. This document needs to clearly define the state of the process implementation, provide a time line for completing the implementation, list any non-conformities to the drawing and/or specifications, and a containment plan to keep those nonconformances from reaching MEI.
Results Enter the appropriate stage of process implementation in regard to manufacturing for serial production. 1. Prototype process is implemented; No released deviation of concession; No containment plan. 2. Interim process implemented, with partial production intent process; No released deviation or concession; No containment plan. 3. Prototype or partially implemented process; Released deviation or concession; No containment plan. 4. Partial or fully implemented process; Released deviation or concession; Containment plan implemented. 5. Fully implemented process; No deviation or concession required
5. Fully implemented process; No deviation or concession required. Launch Readiness Audit
Sub-Component PPAP Approvals
A comprehensive audit tool's score, which assesses a process's state of preparation to meet serial production requirements.
Number PPAPs approved for the purchased sub-components and materials that makes up the final shipped component/material, and that do not have
The score achieved on the Launch Readiness Audit. Enter data as a decimal number. The minimum goal for full release for production is 90%. Goal is 100% and entered as "1". The number of approved sub-component and material PPAPs at the time of the report.
APQP: Key Supplier Metrics Operational Definitions This section defines the Key Supplier Metrics that will be tracked throughout the four APQP Phases. Reviews will be held toward the end of each of the four phases. Review of these metrics, in the Phase 4, will take place before the final full PPAP approval
Metric Supplier Ramp Plan
Definition
Goal
This element evaluates a supplier's ability to meet ramp-up timing and volumes.
Results Enter the number corresponding to the completed stage from the list below. 1. Has not received any production releases from using plant(s). 2. Is receiving production releases from the using plant(s), but no production schedule or plan documented to meet those volumes or has ramp plan, is receiving plant releases, but is not shipping to plan and/or releases . 3. Has not received production releases from plant(s), but has created a preliminary planned based on quoted volumes and program timing. 4. Is receiving production releases and has created a plan, but production schedule does not reflect the plan. 5. Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule.
Enter the goal, Level 5-Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule. Safe Launch Plan (PCM) Deployment
Completion of the PCM is noted by Operations, i.e., plant, approval of the Safe Launch Plan portion of the form.
Enter number of completed stage at time of review.
Supplier APQP: Key Supplier Metrics Report Supplier Name:
Supplier Location:
Supplier Code:
Part Number:
Part Name:
Revision Level:
Component Priority Level:
Lead Customer/Program:
Report Date:
Primary Indicator: Goal Production Preparation Influencing Factors
1. APQP Readiness
Target
Number of 'Progress Report' elements with Green status Total number of elements from 'Progress Report' Total number of instructions completed
2. Process Instructions
K E Y M E A S U R E A B L E S
Y T I L I B 3. First Time Capability A R U T C A F 4. Process Efficiency U N A M
5. Process Capability
6. Test Achievement 7. Process Implementation % Completed 8. Launch Readiness Audit
P A P P 9. Sub-Component PPAP
Total number of instructions needed. Results from Run at Rate Ideal % of good parts Available capacity based on % of cycle time to Takt time achieved Maximum acceptable % of available capacity base on %cycle time to Takt time Number of capable designated characteristics features Total number of designated characteristics f eatures Number of tests passed % of total tests High volume process or Interim Process wi th Concession Production volumes provided off production intent process Score achieved during event Goal is 100%. Number of sub-components and materials PPAP approved
Approvals
Total number of purchased sub-components/materials
10. PPAP Package
Number of PPAP required documents completed
5
Results
Supplier APQP: Supply Chain Map - Example TIER 4 SUPPLIER
TIER 3 SUPPLIER
TIER 2 SUPPLIER
Kojak Heat Treat Benton Harbor, MI Harden & Draw
Anaconda Steel Erie, PA C1038 Rod Steel Mill
White & Jones Jackson, MI C1038 Rod Wire Draw, Anneal
Fine Fasteners, Inc. Benton Harbor, MI M8x20 Weld Stud 59039813A Cold Forming
3rd Party Warehouse
TIER 1 SUPPLIER AAA Heat Treat Frederick, MD Harden & Draw
Pacific Steel Los Angeles, CA C1024 Rod Steel Mill
B&C Processing Georgetown, PA C1024 Rod Wire Draw, Anneal
Dynamic Chemical Supplies Tulsa, OK Coating materials, solvents
ABC Nut Co. Summit, NJ M8x15 Staking Nut 59039812C Cold Forming
Precision Forming Amarrillo, TX Airbag Reaction Can 49019804A Stamping body, end caps, brackets
Saf-Store Mesa, AZ Warehouse Services
CUSTOMER
Magna Electronics Holly, MI
Magna Electronics Monterrey, MX
Zephyr Coatings Austin, TX E-Coat
Supplier APQP: Supply Chain Map Supplier: Tier V
Part Number: Tier IV
Tier III
Date: Tier II
ME Receiving Operation
Revision: OEM Customer
Tier
Supplier APQP: Product Characteristic Matrix Part Name:
Supplier Name:
Rel. Date:
Part Number/ Revision:
Location:
Rev. Date:
Project/ Program:
MEI Using Plant(s):
MEI/ Supplier
# Design Characteristic
Level/ Class
DFMEA Sev.
TIER II - Supplier Process Control PFMEA Occ.
PFMEA Det.
RPN
Control Method/ Equipment
Gauge R&R % Tol
Pp/ Ppk
Safe Launch Plan (SLP) Freq. /Siz e
Cont rol M et hod/ Equi pment
Fr eq./Siz e
Reporting
Characteristic Review Appro val
Name
Position/ Title
Date
Name
Position/ Title
Date
Signature
Additional Comments
MEI SDE MEI Plant SQA Supplier Representative Safe Launch Exit Ap provals
MEI SDE MEI Plant SQA Supplier Representative
Signature
Additional Comments
Cpk/Cp
SLP Exit Criteria
Supplier APQP: Product Characteristic Matrix (Sub-Supplier) Part Name:
Supplier Name:
Rel. Date:
Part Number/ Revision:
Location:
Rev. Date:
Project/ Program:
MEI Using Plant(s):
TRW/ Supplier # Design Characteristic
Level/ Class
DFMEA Severity
Sub-Supplier Process Control PFMEA Occurrence
PFMEA Detection
RPN
Control Method/ Equipment
Gauge R&R % Tol
Pp/ Ppk
Safe Launch Plan (SLP) Freq./Size
Control Method/ Equipment
Freq./Size
Reporting
Characteristic Review Ap proval Name
Position/ Title
Date
Name
Position/ Title
Date
Signature
Additional Comments
MEI SDE MEI Plant SQA Supplier Representative
Safe Launch Exit A pprovals MEI SDE MEI Plant SQA Supplier Representative
Signature
Additional Comments
Cpk/Cp
SLP Exit Criteria
Safe Launch Plan: Weekly QOS Report Pareto Failures By Process
Touch Point Incident & PPM Monitoring 70
12
30000
11 10
10
60
25000
t n e d i c n I
50 20000 t 40 n e d i c n 30 I
10000
20 5000
0
0 W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
6 5
5
5 4
4
0
P
10
7
6
3
3 2
2
M
15000 P
Example
8
0
r e t e m a i d e l o h t n e m t u b A
0
0
0
0
0
r e t e m a i d e l o h r e t s u j d A
k c e h c d a e r h t t u N
0
0
r e t e m a i d e l o h r e d n i l y c l e e h
W29
0
0
n o i t i s o p e l o h e l b a c e k a r B
W Incidents
Fault No.
Failure Mode
Total
Total
WEEK
W16
W17
71
Incidents
65
0
1
5
9350 7594
QTY
2350
W14
3500
3500
PPM
27660
0
286
Action
Timing
W14
W15
W16
Abutment hole diameter
11
11
2
Lining wear inspection hole diameter
10
10
14
Nut thread check
7
7
8
Wheel cylinder hole position
6
6
3
Adjuster hole diameter
5
5
6
Bearing case ID
5
5
7
Wheel cylinder hole diameter
5
5
5
Mounting holes diameter
4
4
9
Brake cable hole position
3
3
11
Threaded nut hole position
3
3
21
NO paint scratch and or contamination, Blistering, runs
2
2
12
Abutment hole position
2
2
20
No Cracks on backplate (visual boundary sample)
2
2
16
Abutment and locating plate gap
0
0
10
Brake cable hole diameter
0
0
19
Locating abutment plate smooth surface
0
0
17
Dust ring gap to backplate check
0
0
18
Cable guide gap
0
0
4
Mounting holes position
0
0
Nut weld torque
0
0
Hold down pin diameter
0
0
1
2 0
s n r u o r , d g n n r a i e h t s c l i t a B r c , s n o t i n t i a a n p i O m a N t n o c
2 0 00 l a u s i v ( ) e l e t a p l p m k a c a s y b r a n d o n s u k o c b a r C o N
00
00
r e t e m a i d e l o h e l b a c e k a r B
W15
00
00
k c e h c e t a l p k c a b o t p a g g n i r t s u D
PPM
13
15
0
00
00
n o i t i s o p s e l o h g n i t n u o M
00
r e t e m a i d n i p n w o d d l o H
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
#VALUE!
#VALUE!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
Supplier APQP: Open Issues - Corrective Action Plan Supplier Name:
Component Manufacturing Location:
Supplier Code:
MEI Part Number(s):
Issued by:
Customer Name: Launch Activity
Item Number
Source of Issue
Distribution:
Customer Platform: Date
Launch Activity
Concern / Problem / Open Issue Description
Date
MEI Product: Launch Activity
Date
Status: Action plan review Date scheduled Date actual
Action plan review Date scheduled Date actual
Dates Action
Opened
Due
Closed
Status
Responsibility
Supplier APQP: Progress Report - Status Overview Supplier Name: Part Number: Component Priority Level:
Supplier Location:
Supplier Code:
Part Name:
Revision Level:
Lead Customer/Program:
Report Date:
PROGRAM MILESTONES Event
Needed
Date Committed
Completed
Event
Needed
Date Committed
Completed
Design Freeze First Off-Tool First Off-Process ME PV Build PPAP submission Start of Production PHASE/ELEMENT STATUS OVERVIEW
Element Needed 1.1 Design FMEA 1.2
1
Percent Complete
Date
APQP Phase
Preliminary Capacity Study reviewed
1.3 Manufacturing Feasibility reviewed 1.4 Component Design Review 1.5 Key Supplier Metrics initiated 1.6 Supplier Project timing plan 1.7 Open Issues Action Plan created 2.1 Measurement/ Testing equipment 2.2 Tooling 2.3 Capital equipment 2.4 Initiate PCM (Safe Launch Plan)
Committed
Complete
0 0 0 0 0 0 2 4 6 8 1
s u t a t S
Issues / Recovery Plan / Actions
PPAP Submission Checklist Magna Part Number: Customer:
Description: Program:
Revision Level: Product Line:
SUPPLIER INFORMATION
MAGNA ELECTRONICS INFORMATION
Company Name:
Product Line:
Company Location:
Using Location:
Supplier Code:
Reviewer:
Contact Name:
Phone:
Review Date:
Contact email:
Disposition: PPAP Level 3 Unless MEI SDE directs "other"
Document
No. 1
Part Submission Warrant A. B. C. D.
E. F. G. H.
I. J.
2
Assessment
PPAP Submission Level 1 S
2 S
3 S
4 5 S R
R
S
S
*
R
R
S
S
*
R
R R
S
*
R
PART NUMBER INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT WEIGHT INCLUDED SUPPLIER MANUFACTURING INFORMATION COMPLETE, INCLUDING SUPPLIER CODE SUBMISSION INFORMATION COMPLETE. 1. ALL APPROPRIATE BOXES CHECKED 2. BUYER NAME INCLUDED 3. APPLICATION INFORMATION INCLUDES MAGNA CUSTOMER AND PROGRAM ELV/IMDS INFORMATION INCLUDED: The Magna Holly IMDS # is 9822 CORRECT REASON FOR SUBMISSION BOX CHECKED 1. IF OTHER IS CHECKED, THAT THE CORRECT REASON FOR SUBMISSION IS NOTED CORRECT SUBMISSION LEVEL BOX IS CHECKED THE SUBMISSION RESULTS AREA IS PROPERLY FILLED OUT AND THE PACKAGE REFLECTS THIS 1. PACKAGE CONTENTS MUST REFLECT SUPPLIER'S STATEMENT OF COMPLIANCE 2. FOR MULTIPLE TOOLS/CAVITIES/PROCESSES THAT THE INFORMATION IS NOTED IF APPLICABLE THE DECLARATION AREA CONTAINS THE RUN AT RATE INFORMATION SIGNATURE AREA IS COMPLETED AND CONTAINS ALL INFORMATION
Design Records (Drawings, Specifications) A. A MARKED OR BALLOONED DRAWING IS ATTACHED. Note: All non reference print items and specs must be addressed. B. COPIES OF ALL REFERENCED SPECIFICATIONS ARE INCLUDED IN THE SUBMISSION (LEVEL 3 ONLY)
3
Change Documents A. B. C. D. E.
4
PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT PART APPLICATION / PROGRAM / PLANTS IDENTIFIED SPECIFIES TIME SPAN OR VOLUME AFFECTED ACTION PLAN INCLUDED IF REQUEST IS FOR DEVIATION/CONCESSION SIGNED AND DATED BY MAGNA ENGINEERING
Customer Engineering Approval Documents
d e d t e t e e r t i l K i O u m p t q b m K e u o o R S C O N
A. CAPABILITY STUDY RESULTS ARE SUBMITTED ON THE PRODUCT CHARACTERISTICS MATRIX (per MAGNA XXX) B. STUDIES ARE CONDUCTED FOR ALL CRITICAL AND SIGNIFICANT CHARACTERISTICS (EXCEPT DIMENSIONS WITH BONUS TOLERANCES). EACH STUDY MUST INCLUDE THE STUDY DATE. C. TEN (10) MEASUREMENTS FOR BONUS TOLERANCE DIMENSIONS ARE INCLUDED or PER MAGNA SDE DIRECTION D. PPK's FOR ALL CHARACTERISTICS ARE GREATER THAN, OR EQUAL TO, 1.67. E. IF NO, A WRITTEN CORRECTIVE ACTION STATEMENT, FOR EACH, IS INCLUDED AND CONTAINMENT, WHEN FEASIBLE, IS 100% INSPECTION. F. RAW DATA IS INCLUDED FOR EACH STUDY G. PROCESS AVERAGES MATCH FOR MULTIPLE CAVITIES, DIES AND TOOL PROCESSES.
11 Measurement Systems Analysis (Gage R&R)
R R
S
*
R
R
S
S
*
R
R R
S
*
R
14 Appearance Approval Report (As Appropriate)
S
S
*
R
15 Bulk Materials Requirement Checklist (As Appropriate)
R R R
*
R
16 Sample Product
R
*
R
17 Master Sample
R R R
*
R
18 Checking Aids
R R
S
*
R
19 Compliance with Customer Specific Requirements
R R
S
*
R
*
*
S
*
*
21 Evidence of ELV / IMDS Approval
*
*
S
*
*
22 Packaging Plan and Sample Label (per MAGNA XXX)
R R
S
*
R
23 RUN-AT-RATE or Capac ity Verification per MAGNA SDE DIRECTION (per MAGNA XXX)
*
S
*
*
A. B. C. D. E. F.
STUDIES ARE INCLUDED (AND DATED) FOR GAGES USED TO MEASURE SIGNIFICANT AND CRITICAL DIMENSIONS. GAGE R& R FORM IS USED FROM MEASUREMENT ANALYSIS HANDBOOK. WRITTEN CORRECTIVE ACTIONS ARE INCLUDED FOR GAGE R&R'S GREATER THAN 30%. THREE (3) OPERATORS, THREE (3) TRIALS ARE U TILIZED. FORMS ARE C OMPLETELY FILLED OUT. WAS THE PROCESS CAPABILITY CALCULATED MADE OFF PARTS MADE FOR PPAP SUBMISSION?
12 Qualified Laboratory Documentation A. CERTIFICATE OF ACCREDITATION IS FROM A NATIONALLY RECOGNIZED ORGANIZATION. B. SCOPE OF ACCREDITATION IS INCLUDED.
13 Control Plan A. B. C. D. E. F. G.
PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT DOES CONTROL PLAN REFLECTS LAUNCH PRACTICE ITEMS? DOES IT SHOW SAME REVISION LEVEL AS PFMEA? CONTROL PLAN ADDRESSES ALL SIGNIFICANT AND CRITICAL DIMENSIONS. CONTROL PLAN ADDRESSES THE ENTIRE PROCESS FROM R ECEIPT OF MATERIAL TO SHIPPING PRODUCT. CONTROL PLAN INCLUDES ANNUAL REVALIDATION REQUIREMENTS. CRITICAL FEATURES IDENTIFIED ON THE PCM, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS, CRITICAL PROCESS CONTROLS, ETC.) ARE INCLUDED IN THE PFMEA AND HAVE RPN CALCULATED.
S
S
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A. DOCUMENT(S) DEMONSTRATING COMPLIANCE WITH ANY OEM SPECIFIC COMMUNICATED REQUIREMENTS.
Additional MAGNA SPECIFIC PPAP Requirements 20 Product Characteristic Matrix (per MAGNA XXX) A. ALL SUB-TIER SUPPLIERS HAVE BEEN INCLUDED BASED ON SUPPLY CHAIN MAP. B. ALL SIGNIFICANT AND CRITICAL DIMENSIONS ARE INCLUDED, AND FOLLOW BACK TO THE MANUFACTURING PROCESS THAT PRODUCES THEM. C. PFMEA RPN'S ARE INCLUDED FOR ALL INCLUDED DIMENSIONS. D. CUSTOMER TOUCH POINTS AND CRITICAL PROCESS CONTROLLED DIMENSIONS ARE INCLUDED. E. SAFE LAUNCH PLAN DOCUMENTS CONTROLS THROUGHOUT THE SUPPLY CHAIN UP TO MAGNA.
A. DOES THE SUPPLIER NEED TO INCREASE THEIR CAPACITY?
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PPAP Submission Folder Instructions:
For the submission of each Part Number, please utilize the MEI PPAP Checklist and insert the appropriate PPAP document into its respective folder within the Zip File Master. If a document is not relevant/required, submit an insert that notes that that element is not applicable. Examples are often AARs and DFMEAs.
Part Number
MEI APQP: Contacts- APQP TEAM
Report Date / Revision
Contact Information Function
MEI Purchasing Commodity Buyer
MEI Purchasing Program Buyer
MEI Supplier Development Engineering
MEI Engineering
MEI Receiving Plant Logistic & Packaging
MEI Receiving Plant Quality
Project Management
Contact Information
Supplier
Function Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location
Chris Hempsall Purchasing 810-603-4137
[email protected]
Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location Name Dept. Tel. Fax. E-mail Address/ Location
