Procedure APQP

ASIAN AUTOMOTIVE AUTOMOTIVE STEELS

12.08.10 Customer request Development

CONTRACT REVIEW

Marketing Development

Customer RFQ product documents delivery requirements (customer statement) Customer Credit Check

Credit Critera failed

Marketing Credit / Audit Report

Project risk assessment

Vendor information

RFQ vendor

SGM / GM authorization

outsource

Vendor RFQ

Vendor feedback No go

Request Customer Specific Requiremen

Preliminary RFQ analysis

Quotation reject, Counter proposal Development Manufacturing Purchasing Engineering

CSR

Statement of Deliverables (internal RFQ form) Preliminary process flow APQP checklist Draft APQP organization chart

Vendor preliminary proposals

Technical feasibility

Reject

APQP team counter proposal

Accept: Team Feasibility Commitment m/c cycle time Costing assumption

Preliminary planning

Development

Project Development Costing Manufacturing costing Preliminary project schedule Project FS

Accounts

FS documents

Document compilation Quotation analysis, Proposal Quotation letter

Marketing Change request

Management support

Marketing

GM, SGM Endorsement

Inform customer

Close project order

MD/COO approval

Change request Marketing

Signed quotation Project Authorization RFQ rejection memo

Document submission

Marketing

Customer quotation forms, packaging Delivery/Acceptance Delivery/Acceptance document Project close

No reject letter from customer

Customer accept?

Record in quotation file

LOI / LOA

Quotation file

Product Design & Development

File: Procedure APQP.vsd

Page 1

Marketing

Prepared: AG


12.08.10

CONTRACT AMMENDMENT & VA/VE

Engineering change proposal Customer ECN/ change product documents delivery requirements Technical concept study Technical feasibility evidence Preliminary Go/No Go

Counter Proposal

GM endorsement, customer endorsement Commercial Feasibility Feasibility not OK Team feasibility commitment not OK

Commercial feasibility study Commercial Feasibility study OK Team Feasibility commitment OK Start decision proceed

outsource

Not feasible

RFQ approved vendor Vendor RFQ Vendor feedback Vendor proposals

Preliminary Preliminary planning

Preliminary process analysis Project Development Costing Manufacturing costing Preliminary project schedule Project feasibility study

Change request

Document compilation

Analysis documents documents

Preliminary Preliminary quotation

Quotation Letter

Counter proposal

Change request

GM endorsement

Counter propose

Forward to MD MD/SGM endorsement

Counter proposal

Signed quotation Project Authorization Trasmit to customer

Confirmation of receipt Customer accept? LOI / LOA/ PPA ammendment product development File: Procedure APQP.vsd

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12.08.10

PRODUCT DESIGN & VALIDATION LOI / Customer authorization

Yes, resourcing / localization

Design document avail?

No, new design product validation req

Sample available?

no

Customer liaison

Correspondents, Correspondents, minutes Customer product specs, stds avail?

Customer needs analysis

yes No / incomplete

Customer requirements Reverse engineering Yes; drawing, spec, testing std

revise

Quality Requirement analysis

Product specification proposal

Bill of materials incoming material requrement process requirements Specification list

Product design / verification manual calculations FEA output product design drawing proto pfmea, control plan

testing list approval Customer-approved PIS, testing list

Prototype part, interfaces purchase / mfg

Product validation Test planning/design

Testing documentation requirement

Test eqpt, method requirement

Test document preparation

Testing arrangement equipment prep

product std

Sample purchase documents

Product analysis QFD / DFMEA

QFD, DFMEA form

(Specifications not compatible, emerging Requirements) Product Change Request

sample parts Fitting, performance analysis

Fitting trial checksheet Testing checksheets

Status reports inspection checksheet template

Prototype testing, analysis

Sample testing results

Spec review / DQCM

PRODUCT SPECIFICATIONS Product drawing (comp & assy) Testing specification, Part Inspection Standard Packaging specification Product document release


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12.08.10

PRODUCT DOCUMENT RELEASE Product specification specification product document draft / update/ correction draft drawing

document log update

update drawing log change request

customer EC approval req?

yes

EC Request no

(customer preliminary document review) approve for final submission

final document preparation

final document

document check check - approve approve

signed document

document submission

proof of delivery

contract ammendment req?

customer endorsement

yes

customer-approved customer-approved document

Document Control

Contract Ammendment no

Process development planning


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12.08.10

PROCESS DEVELOPMENT PLANNING LOI / LOA + Product Specifications Specifications Process requirement analysis Process flow diagram PFMEA Special Process characteristics characteristics

Sourcing plan

Production Process, inspection planning Production Control Plan Pre-launch Control Plan Factory layout, manpower plan Material, component sourcing

Engineering Development Analysis

DevelopmentInspection / test eqpt spec MSA plan

Development process flow Process validation plan Prelaunch control plan Equipment Specifications Specifications Development project planning

Testing inst development/acq analysis

Test eqpt requirement / devp plan

Production m/c requistion /eng development plan Development Project schedule, resource requirement, cost estimate

Final proposal preparation / revision Change request

Project Proposal Management review

change request

Authorization to proceed Confirmed project plan

Transmit final proposal to customer management approved proposal Customer review

Process Development & Validation


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12.08.10

PROCESS DEVELOPMENT & VALIDATION Authorization to proceed

PROCESS VA VALIDATION

ENGINEERING DE DEVELOPMENT

Inst purchase/ devp / mod / training

Eqpt purchase/devp/ mod

Vendor selection

A9 checking aids aids inspection jig

Purchasing records

Vendor LOI

checksheet confirmation

Equipment testing / checksheets

product characteristic ng

test equipment fail

VENDOR DEVELOPMENT

mc ng Agreement not possible

Equip testing checksheet

Part inspection standard devp Vendor drawing Draft PIS

Eqpt testing

Approved checksheets checksheets

arbitration

Equip / test reports

Hard tooling Product samples

Change terms Vendor Devp failed

Vendor inspection agreement development contract / LOA approved quality checksheets

Line trials

line operation status OK improvement areas

Vendor development

line improvement

Vendor progress reports

Product testing

Dimensional inspection report, AAR, testing report

Product evaluation

improvement needed

Vendor monitoring

Line trials

Child part ng

sample submission

Sample approval

Vendor evaluation sample

Child part testing preliminary PFMEA update

Module testing results Child part evaluation Child part approval pp appointment

satisfactory RPN

Vendor PP

Vendor pp summary Approval Record Record master parts

MASS PRODUCTION PREPARATION

Subsupplier PQCM sign-off

Vendor PQCM

signed vendor PSW minutes PQCM Vendor LOA, draft PPA draft LOA, PPA

contract nego

term agreement

Vendor PPA File: Procedure APQP.vsd

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12.08.10

MASS PRODUCTION PREPARATION process development review prelaunch control plan updated prelaunch, production control plan list equipment, instrument, work instruction, QC checksheets, manpower list material & child part ordering prelaunch preparation meeting prelaunch checksheet updata

QC checksheet preparation

prelaunch, production work instruction preparation

equipment servicing, instrument MSA

prelaunch production planning

prelaunch material order

preparation monitoring

not ready

prelaunch checksheet complete

prelaunch briefing small batch trial production product, process data minor issues

product audit process ok line production confirmation trial product, process data product audit

major issues

process ok Process Development

line run at rate

Quality Council Enquiry

Customer PQCM/PCPN Sign-off PQP Summary & Sign-off Production part documentation compilation correction request


APQP records records

Project Exit Review

PPAP, Pqcm report

minutes

PQCM

Quality document update

PSW Sign off

project file document update product quality standard update

Early production containment

Project APQP doc QMS update

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12.08.10

KAIZEN / PROCESS IMPROVEMENT

SCHEDULED PRODUCTION

Improvement needed?

Operational problem Production QC report

no Quality problems?

Quality problem

Improvement possible Problem analysis

Kaizen request for proposals

Improvement ideas Kaizen submission

Additional Testing Testing / data gathering

Kaizen Evaluation Proposal accepted

Test reports, data analysis Project planning

Kaizen proposal

Minutes project schedule

Modification

Tooling / mc redesign, fabrication

Problem description

Temp rigging, work inst

Temporary production rigging, work inst

Process ref update m/c maintenance log update Off-line testing

m/c maintenance log update Problem resolved? Target achieved Supervised production

Statistical data PFMEA updates process improvement activities update SPC data update

Acceptable?

improvement project close


Kaizen award presentation

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12.08.10

PROJECT GO/NO-GO DECISION

Volume commitment Material cost quotation

Dev cost estimate

Compute costs / pc, capital investment

Process cost estimate

Standard costing sheets

Marginal cost meet customer price?

No Yes

Management prerogative

No

Full costing meet customer price?

Yes Project Authorization Memo

TH

4 down & 20 GO FOR IT!

Quotation issue

Inform customer NG


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Prepared: AG

Procedure APQP

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