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Supplier APQP: Four Phases

Magna Electronics (MEI) - 4 Phases of APQP for Supplier Development Engineering


APQP -> Phase 1
Supplier Kick-Off and Planning
Identify MEI and Supplier team contacts/roles/responsibilities

APQP -> Phase 2


Product/Process Realization
Create and/or review DFMEA as appropriate depending upon design resp.

APQP -> Phase 3


Pre-PPAP

APQP -> Phase 4


Product/Process Validation and Launch

Pre-production run

Finalize complete PPAP submission package

Communicate and initiate Key Supplier Metrics

Develop process flow chart (diagram).

Process capability study

Cross functional key metrics review: Launch sign off

Initial Supplier Program plan and timing

Create & review preliminary process flow diagram, PFMEA, and Control Plan.

Finalize PCM: prepare for Safe Launch

Launch Readiness Audit

Conduct Cross-functional component design review (doc is located in GSQM)

Finalize PCM & use document for any preproduct part runs.

Finalize PFMEA and Control Plan

Confirmation of full 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

APQP Requirements

Develop Process Instructions

Launch Readiness Audit: document key metrics

Initiate Safe Launch practice & review supplier's data for appropriate actions.

Equipment Tooling & gage concept/design review.

Finalize Process capability study Plan

Re-qualify equipment, tooling & gaging as it moves between supplier site(s)

Review Key Supplier Metrics

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 appropriate)

Close-out previous phase open issues and key documents

Review supplier's manufacturing feasibility document(s) Review preliminary capacity study & initial supplier master schedule plan

Floor plan layout

Supplier participates in Plant Readiness Review

Update previous phase open issues and key documents

Review status of Key Supplier Metrics

Iniate Open Issues Document

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 APQP Woorkbook

Process Owner/Department: Chris Hempsall Approved by: Justin Reaume / Pur Dir

Supplier APQP: Table of Contents


Cover Table of Contents Shows the 4 APQP Phases and the activities that occur within them. 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. 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 assumption that the supplier will be providing product that is fully compliant to all applicable drawings and specifications. 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 have software available to meet this requirement, a blank time line is provided for their use. Operational definitions for the twelve key metrics. Explains the metric and its method of calculation.

Supplier Feasibility Statement

Blank Time Line

Key Metrics Definitions

Key Metrics Report

Key Metrics contain those elements that contribute to a successful launch. This form allows for four 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 location. This establishes a baseline performance on the process in its "as received" state. The APQP-4 report is generated at the time product is 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. An example of how a Supply Chain Map may appear for a typical metal component.

Supply Chain Map Example 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). The PCM is used initially to define and determine appropriate controls for special characteristics, other process critical features and customer touch points. This tab is used to define the process at 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 Characteristics Matrix Tier II

Product Characteristics Matrix Sub-Supplier

The use of this tab is identical to the functionality define above, with the exception that this is used to document the remaining supply chain's, below the Tier II supplier, impact on the critical features.

PCM - Weekly QOS Report

Format to be used for a weekly summary of the inspection results from the Safe Launch Plan. This information will be used as part of the decision making process for the removal of the Safe Launch Controls.

Open Issues

The action plan format used to document open issues, their actions and resolution throughout the APQP process. This combines several different action plans generated by different, individual tools into a single document.

MEI PPAP Checklist & Document ".ZIP" Folder

It is an expectation of MEI that the PPAP Checklist is used for each new part submission to make sure that all required PPAP elements are submitted free of the errors that have been historical observed. MEI is confident that if the PPAP Checklist is used that it will help insure expedited PPAP approval. Please use the embedded PPAP ".ZIP folder" to make sure that all required PPAP elements are submitted in a softcopy format that helps with ease of review and document storage. Lists the individuals involved in the component(s) launch, for both MEI and the supplier, and their respective contact information. This tab is optional and may be used as needed.

Contacts

Magna Electronics APQP Workbook Date: 14 May, 2008 Revision: A

Process Owner/Department: Chris Hempsall Approved by: Justin Reaume

Supplier Design Review Sign Off


Part Name: 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.

Part No.:

Date: ________________

Rev. No.:

YES

NO

Considerations
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 / uncommon materials required that 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

Sign-Offs: Magna Electronics Name: Title: Signature: Date: Name: Title: Signature: Date: Supplier _____________________________ Name: Title: Signature: Date: Name: Title: Signature: Date:

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 illustrates 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. APQP PHASE Year 1 OUTPUT
02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50

Year 2
52

1. Supplier Kick-Off

1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 4.4 4.5 5.1 5.2 5.3 5.4 5.5 5.6 5.7

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 Tooling Capital equipment Training 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

5. Other Requirements

4. Product/ Process Validation &

3. Pre-PPAP

2. Product/Production Realization

KEY:

X Planned start

Planned completion

Actual start

>

Actual end

Magna Electronics APQP Workbook

Supplier APQP: Blank Time Line


APQP PHASE Year 1 OUTPUT
02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50

Year 2
52

1. Supplier Kick-Off

1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 4.4 4.5 5.1 5.2 5.3 5.4 5.5 5.6 5.7

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 Tooling Capital equipment Training 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

5. Other Requirements

4. Product/ Process Validation &

3. Pre-PPAP

2. Product/Production Realization

KEY:

X Planned start

Planned completion

Actual start

>

Actual end

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 APQP Readiness

Definition 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.

Goal

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 total number of process instructions needed for serial production.

Enter number of completed process instructions at the time of the review.

First time Capability

Percentage of good parts to the total number of parts produced during the Run at Rate. Enter the number '1,' which represents the production of 100% good, or usable, parts.

Enter, as a decimal number, the ratio of total parts produced to good parts from the trial run.

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 number of designated characteristics with a Ppk > 1.67.

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 Enter the number of characteristics, with a Ppk > 1.67, at the time of the review. Enter the total number of designated characteristics on the drawing.

Process Capability

Test Achievement

Total number of performance and materials tests that need to be conducted to meet the specifications shown on the drawing. This number is a combination The should represent the total number of of the number of unique tests multiplied individual tests required times the number by the number of samples required for of samples, for each test, that is required. the test.

This is the total number of samples that passed all of the required testing at the time of the review.

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

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

APQP Readiness is derived from the Progress Process Implementation - Data This metric assesses the'APQP level of Report'. This metric tracks the % Completed implementation of the full production percentage of GREEN elements intent process. Processes that are not compared to the total number of fully implemented at the Start-ofelements being tracked. Production 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.

5. Fully implemented process; No deviation or concession required. Launch Readiness Audit A comprehensive audit tool's score, which assesses a process's state of preparation to meet serial production requirements. 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.

Sub-Component PPAP Approvals

Number PPAPs approved for the purchased sub-components and materials that makes up the final shipped component/material, and that do not have The number of approved sub-component any deviations, waivers, and/or and materials making up the shipped concessions granted by any tier below component/material. MEI. Number of PPAP submission package elements completed compared to required number. The total number of required elements, or documents, required to be submitted.

PPAP Package Completion

The number of elements (or documents) completed for the PPAP package at the time of the review.

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 APQP Readiness Supplier Ramp Plan

Definition Data element is derived from thea 'APQP Progress This evaluates supplier's ability Report'. This metric tracks to meet ramp-up timing andthe volumes. percentage of GREEN elements compared to the total number of elements being tracked.

Goal

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. Enter the number '5' representing the completion of the PCM, less the exit from the Safe Launch Plan. This applies to situations where the PPAP will be submitted in a span of time from before SOP to 30 days after SOP.

Stages of completion are: 1. MEI's supplier has completed the form, less SLP. 2. MEI's supplier has completed their sub-supplier form, less SLP. 3. Supplier section completed, including Enter the number '6' for situations where SLP. the SLP exit is required for closing APQP. 4. Sub-supplier section completed, including SLP. 5. Characteristic Review signed off on both tabs. 6. Complete sign-off on both tabs for "Safe Launch Exit Approval.

Supplier APQP: Key Supplier Metrics Report


Supplier Name: Part Number: Component Priority Level: Supplier Location: Part Name: Lead Customer/Program: Supplier Code: Revision Level: Report Date:

Primary Indicator: Goal Production Preparation Influencing Factors Number of 'Progress Report' elements with Green status 1. APQP Readiness Total number of elements from 'Progress Report' Total number of instructions completed 2. Process Instructions MANUFACTURABILITY Total number of instructions needed. Results from Run at Rate 3. First Time Capability 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 5. Process Capability Total number of designated characteristics features 6. Test Achievement 7. Process Implementation % Completed 8. Launch Readiness Audit 9. Sub-Component PPAP Approvals 10. PPAP Package Completion 11. Supplier Ramp Plan DLN 12. Safe Launch Plan (PCM) Deployment Number of tests passed % of total tests High volume process or Interim Process with Concession Production volumes provided off production intent process Score achieved during event Goal is 100%. Number of sub-components and materials PPAP approved Total number of purchased sub-components/materials Number of PPAP required documents completed Number of PPAP required documents required State of completed supplier ramp plan Ramp planned completed and shipping to releases Enter completed stage of PCM (see comments) Complete Stage 5 by SOP 5 Metrics Overall Score #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! 5 5 Target Results

K E Y M E A S U R E A B L E S

4. Process Efficiency

SUPPLIER SIGN-OFF (MANAGER LEVEL) Function Name (print) Signature Project Leader Purch/Sales Production Control Quality Engineering Design Manufacturing

MEI SIGN-0FF SDE MEI Internal Use only Commodity Mgr/Buyer SQA Name (print) Name (print) Name (print) Signature Signature Signature

PPAP

Supplier APQP: Supply Chain Map - Example


TIER 4 SUPPLIER TIER 3 SUPPLIER TIER 2 SUPPLIER

Kojak Heat Treat Benton Harbor, MI Harden & Draw Fine Fasteners, Inc. Benton Harbor, MI M8x20 Weld Stud 59039813A Cold Forming

Anaconda Steel Erie, PA C1038 Rod Steel Mill

White & Jones Jackson, MI C1038 Rod Wire Draw, Anneal

3rd Party Warehouse TIER 1 SUPPLIER

CUSTOMER

AAA Heat Treat Frederick, MD Harden & Draw 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

Magna Electronics Holly, MI

Pacific Steel Los Angeles, CA C1024 Rod Steel Mill

B&C Processing Georgetown, PA C1024 Rod Wire Draw, Anneal

Magna Electronics Monterrey, MX

Dynamic Chemical Supplies Tulsa, OK Coating materials, solvents

Zephyr Coatings Austin, TX E-Coat

Supplier APQP: Supply Chain Map


Supplier:
Tier V Tier IV

Part Number:
Tier III Tier II

Date:
ME Receiving Operation

Revision:
OEM Customer Tier

Supplier APQP: Product Characteristic Matrix


Part Name: Part Number/ Revision: Project/ Program: Supplier Name: Location: MEI Using Plant(s): Rel. Date: Rev. Date:

MEI/ Supplier

TIER II - Supplier Process Control


PFMEA Occ. PFMEA Det. RPN Control Method/ Equipment Gauge R&R % Tol Pp/ Ppk Freq./Size Control Method/ Equipment

Safe Launch Plan (SLP)


Freq./Size Reporting Cpk/Cp SLP Exit Criteria

#
Design Characteristic

Level/ Class

DFMEA Sev.

Characteristic Review Approval Name MEI SDE MEI Plant SQA Supplier Representative Safe Launch Exit Approvals Name MEI SDE MEI Plant SQA Supplier Representative Position/ Title Date Signature Additional Comments Position/ Title Date Signature Additional Comments

Supplier APQP: Product Characteristic Matrix (Sub-Supplier)


Part Name: Part Number/ Revision: Project/ Program: Supplier Name: Location: MEI Using Plant(s): Rel. Date: Rev. Date:

TRW/ Supplier
# Design Characteristic Level/ Class DFMEA Severity PFMEA Occurrence PFMEA Detection RPN

Sub-Supplier Process Control


Control Method/ Equipment Gauge R&R % Tol Pp/ Ppk Freq./Size Control Method/ Equipment

Safe Launch Plan (SLP)


Freq./Size Reporting Cpk/Cp SLP Exit Criteria

Characteristic Review Approval


Name MEI SDE MEI Plant SQA Supplier Representative Position/ Title Date Signature Additional Comments

Safe Launch Exit Approvals


Name MEI SDE MEI Plant SQA Supplier Representative Position/ Title Date Signature Additional Comments

Safe Launch Plan: Weekly QOS Report


Touch Point Incident & PPM Monitoring
70 60 50 20000 Incident PPM 40 15000 30 30000
12
10

Pareto Failures By Process


11 10 8 6 4 2 0
0
No Cracks on backplate (visual boundary sample) Brake cable hole diameter Dust ring gap to backplate check Mounting holes position Abutment hole diameter

Incident

25000

6 5 5 5 4 3 0 0
Nut thread check

3
2 2 2

0
Adjuster hole diameter

0
Wheel cylinder hole diameter

0
Brake cable hole position

0
NO paint scratch and or contamination, Blistering, runs

00

00

00

00

00

00

00

00
Hold down pin diameter

Example
20 10 0 W14 W15 W16 W17 W18 W19 W20 W21
Incidents

10000

5000

0 W22 W23 W24 W25 W26 W27 W28 W29

PPM

Total 71 9350 7594


Fault No. 13 2 14 8 3 6 7 5 9 11 21 12 20 16 10 19 17 18 4 15 1 Failure Mode Abutment hole diameter Lining wear inspection hole diameter Nut thread check Wheel cylinder hole position Adjuster hole diameter Bearing case ID Wheel cylinder hole diameter Mounting holes diameter Brake cable hole position Threaded nut hole position NO paint scratch and or contamination, Blistering, runs Abutment hole position No Cracks on backplate (visual boundary sample) Abutment and locating plate gap Brake cable hole diameter Locating abutment plate smooth surface Dust ring gap to backplate check Cable guide gap Mounting holes position Nut weld torque
Hold down pin diameter

WEEK Incidents QTY PPM Timing

W14 65 2350 27660 W14

W15 0 3500 0 W15

W16 1 3500 286 W16

W17 5 #VALUE! W17

W18

W19

W20

W21

W22

W23

W24

W25

W26

W27

W28

W29

#VALUE! W18

#DIV/0! W19

#DIV/0! W20

#DIV/0! W21

#DIV/0! W22

#DIV/0! W23

#DIV/0! W24

#DIV/0! W25

#DIV/0! W26

#DIV/0! W27

#DIV/0! W28

#DIV/0! W29

Total 11 10 7 6 5 5 5 4 3 3 2 2 2 0 0 0 0 0 0 0 0

Action

11 10 7 6 5 5 5 4 3 3 2 2 2 0 0 0 0 0 0 0 0

Supplier APQP: Open Issues - Corrective Action Plan


Supplier Name: MEI Part Number(s): Customer Name: Launch Activity Date Launch Activity Customer Platform: Date Launch Activity MEI Product: Date Component Manufacturing Location: Supplier Code: Issued by: Status: Action plan review Date scheduled Date actual Action plan review Date scheduled Date actual

Item Number

Source of Issue

Concern / Problem / Open Issue Description

Dates Action Opened Due Closed Status Responsibility

Distribution:

Supplier APQP: Progress Report - Status Overview


Supplier Name: Part Number: Component Priority Level: PROGRAM MILESTONES Event Design Freeze First Off-Tool First Off-Process ME PV Build PPAP submission Start of Production PHASE/ELEMENT STATUS OVERVIEW APQP Phase Status Date Element 20 Needed 1.1 Design FMEA 1.2 1 Preliminary Capacity Study reviewed Committed Complete Percent Complete 100 40 60 80 Needed Date Committed Completed Event Needed Date Committed Completed Supplier Location: Part Name: Lead Customer/Program: Supplier Code: Revision Level: Report Date:

Issues / Recovery Plan / Actions

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) 2.5 Sub-Supplier PPAPs 2.6 Process Flow Diagram

2.7 PFMEA 2.8 Control Plan 2.9 Training 2.1 Process instructions 2.11 Packaging 2.12 Launch Readiness Audit 2.13 Key Supplier Metrics reviewed 3.1 ELV/IMDS 3.2 Safe Launch Plan finalized 3.3 Supplier Ramp Plan 3.4 Plant Readiness Review 3.5 Launch Readiness Audit 3.6 Appearance Approval Process (when applicable)

3.7 Key Supplier Metrics reviewed 4.1 PPAP 4.2 Launch Readiness Audit 4 4.3 Run at Rate 4.4 Key Supplier Metrics reviewed 4.5 OK to Launch Sign-Off

PPAP Submission Checklist


Magna Part Number: Customer: Program: SUPPLIER INFORMATION Company Name: Company Location: Supplier Code: Contact Name: Contact email: Phone: Description: Product Line: MAGNA ELECTRONICS INFORMATION Product Line: Using Location: Reviewer: Review Date: Disposition:
PPAP Level 3 Unless MEI SDE directs "other"

Revision Level:

Submitted

Complete

Required

No. 1 Part Submission Warrant


A. B. C. D.

Document
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

1 2 3 4 5 S S S S R

E. F. G. H.

I. J.

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)

R S S

Change Documents
A. B. C. D. E. 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

R S S

Customer Engineering Approval Documents


A. IF PROCESS INCORPORATES UNRELEASED CHANGE, COPY OF ENGINEERING DOCUMENT INCLUDED

R R S

Design FMEA
A. B. C. D. PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART? DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT? AREAS OF CONCERN IDENTIFIED IN THE DFMEA ARE CARRIED OVER INTO THE PFMEA.

R R S

Process Flow Diagram


A. PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT B. MUST START WITH RECEIVING AND FINISH WITH SHIPMENT OF MATERIAL C. PROCESS FLOW DIAGRAM IS ACCURATE

R R S

Process FMEA
A. B. C. D. E. PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART? WHERE APPROPRIATE, DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT? ARE CONCERNS INCLUDED THAT WERE DISCOVERED IN EARLY STAGES? CRITICAL FEATURES IDENTIFIED ON THE PCM/SLP, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS, CRITICAL PROCESS CONTROLS, ETC.) ARE INCLUDED IN THE PFMEA AND HAVE RPN CALCULATED.

R R S

Dimensional Results
A. ALL DIMENSIONS AND NOTES ON THE DRAWING ARE INCLUDED IN THE INSPECTION REPORT B. THERE IS A SEPARATE REPORT FOR EACH CAVITY, DIE, TOOL, LINE, ETC. EXCEPTIONS CAN ONLY BE GRANTED BY MAGNA SDE.

R S S

C. WHEN SAMPLES ARE SUBMITTED, THE SAMPLE NUMBER CORRESPONDS WITH (SERIALIZED TO) THE DATA D. IF NON-CONFORMANCES ARE DOCUMENTED, THE WARRANT LETTER DOES NOT STATE COMPLIANCE. IT IS THE EXPECTATION OF MAGNA THAT NON-CONFORMANCES ARE RECONCILED PRIOR TO PPAP SUBMISSION.

E. DIMENSIONS ARE REPORTED IN THE SAME UNITS AS ON THE MAGNA OR CUSTOMER DRAWING F. LAYOUTS OF SUBCOMPONENTS AND/OR ASSEMBLIES ARE DOCUMENTED AND AVAILABLE

Material & Performance Test Results


A. ALL SPECIFICATIONS ON DRAWING ARE INCLUDED. COPIES OF ACTUAL SPECs ARE INCLUDED IN THE PACKAGE B. ACTUAL TEST LABORATORY DATA IS INCLUDED IN THE PACKAGE C. CERTIFIED LABORATORY USE (INCLUDED ARE COPIES OF CERTIFICATION AND SCOPE OF ACCREDITATION) D. DATA SHOWS TEST REQUIREMENTS AND RESULTS FOR EACH TEST, DETAILED IN EACH SPECIFICATION REFERENCED ON THE DRAWING E. MAGNA PART NUMBER AND REVISION LEVEL ARE INCLUDED ON EACH PAGE FOR ALL DATA

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10 Initial Process Study

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Not OK

PPAP Submission Level

Assessment

OK

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)


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 UTILIZED. FORMS ARE COMPLETELY FILLED OUT. WAS THE PROCESS CAPABILITY CALCULATED MADE OFF PARTS MADE FOR PPAP SUBMISSION?

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12 Qualified Laboratory Documentation


A. CERTIFICATE OF ACCREDITATION IS FROM A NATIONALLY RECOGNIZED ORGANIZATION. B. SCOPE OF ACCREDITATION IS INCLUDED.

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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 RECEIPT 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.

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14 Appearance Approval Report (As Appropriate) 15 Bulk Materials Requirement Checklist (As Appropriate) 16 Sample Product 17 Master Sample 18 Checking Aids 19 Compliance with Customer Specific Requirements
A. DOCUMENT(S) DEMONSTRATING COMPLIANCE WITH ANY OEM SPECIFIC COMMUNICATED REQUIREMENTS.

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* * * * * *

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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.

21 Evidence of ELV / IMDS Approval 22 Packaging Plan and Sample Label (per MAGNA XXX) 23 RUN-AT-RATE or Capacity Verification per MAGNA SDE DIRECTION (per MAGNA XXX)
A. DOES THE SUPPLIER NEED TO INCREASE THEIR CAPACITY? B. ARE BOTTLENECKS IDENTIFIED AND RESOLVED? ARE THERE ANY TOOLING CONSTRAINTS?

* * *

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24 Sub - contractor PPAP status


A. IS THERE A PSW FOR EACH COMPONENT AND MATERIAL IDENTIFIED IN THE BOM AND OR PCM? B. ARE THE PSW'S FULLY APPROVED? IF NOT, IS THERE A MAGNA DEVIATION/CONCESSION FOR EACH PSW NOT FULLY APPROVED?

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25 Critical process approval (Heat treat, plating)


A. ARE THERE ANY CRITICAL SECONDARY PROCESSED THAT REQUIRES USE OF A RECOMMENDED SUPPLIER OR A MAGNA AUDIT BEFORE THEY ARE USED?

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26 Certification of Review** (per MAGNA XXX)


APPLIES ONLY TO SUPPLIERS TO FOR WHICH THE COMMERCIAL SITUATION DOES NOT ALLOW A. FOR FULL DISCLOSURE.

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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


Contact Information 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 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

Report Date / Revision

Contact Information

Supplier

MEI Purchasing Commodity Buyer

MEI Purchasing Program Buyer

Chris Hempsall Purchasing 810-603-4137 chris.hempsall@magnaelectronics.com

MEI Supplier Development Engineering

MEI Engineering

MEI Receiving Plant Logistic & Packaging

MEI Receiving Plant Quality

Project Management