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Supplier APQP Workbook

Advanced Product Quality Planning (APQP) Guideline


Fundamentals of the APQP Process
Advanced Product Quality Planning (APQP) Advanced Product Quality Planning (APQP) is a structured method for defining and executing the actions necessary to ensure a product satisfies the customer. APQP is program and supplier-led and is required of all systems, subsystems and component manufacturing locations - as identified by Westport Supplier Plan and internal APQP procedure. This includes both internal and external suppliers to Westport.

The Goal of APQP The goal of APQP is to facilitate communication between all persons and activities involved in a program and ensure that all required steps are completed on time, with a high quality-of-event, at acceptable cost and quality levels.

The Purpose of APQP Planning of Product Realization is a requirement per ISO/TS. Whether the supplier is ISO 9001 or ISO/TS 16949 certified, the supplier must plan and develop the processes needed for product realization. In Planning of Product Realization following must be determined as appropriate: - Quality Objectives and Requirements for the product - The need to establish processes, documents, and resources specific to the product - Required verification, validation, monitoring, inspection and test activities specific to the product and the criteria for product and acceptance - Records needed to provide evidence that the realization processes and resulting product meets requirements The APQP, as a reference, is a proposed Planning of Product Realization by AIAG (Automotive Industry Action Group). The Purpose of this workbook is to provide requirements and methodology to Westport's Suppliers towards effective implementation of the APQP activities. The Applicability of APQP All Programs under development that require new or modified components (as identified in the Westport Project Charter). It can be used at discretion of the Supplier Development Engineer (SDE) for: - any new manufacturing processes at Suppliers - Significant Product changes - Significant Process changes

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Fundamentals-Introduction

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Supplier APQP Workbook

Teams The first step in the APQP Process is to assign responsibility to a cross-functional team. Effective product quality planning requires the involvement from all areas within a corporation. The team includes representatives from engineering, manufacturing, material control, purchasing, quality, sales, field service, subcontractors, and customers as appropriate.

Responsibility The Supplier is responsible : - to develop and execute an APQP Plan for successful product launch The Suppliers is responsible for ensuring their subcontractors apply APQP methodology and integrating their subcontractors planning in their overall APQP plan - to assign resources to the cross-functional APQP team: - identifying the project team leader, core team members and internal and external customers - defining roles and responsibilities for the team members - to monitor the progress of the APQP and assure successful completion of all APQP elements on time Westport is responsible: - to assign the SDE who shall audit/monitor the satisfactory completion of all applicable APQP activities described in this process - assign the Westport core team members in the different functions (e.g. Buyer)

APQP Flow / Elements The Westport APQP Process has five main functions and includes elements per AIAG Advanced Product Planning and Control Plan manual and Westport unique elements as appropriate. 1 APQP - Kick Off 2 APQP - Product Design The intent of the APQP Product Design review is for the Supplier to understand early enough all the technical specifications of the components supplied and agrees on the feasibility of these specifications. 3 APQP - Process Design The intent of the APQP Process Design review is to formalize Supplier progress on Process Development, understand early enough all the process requirements and documentation of these specifications. 4 APQP - PPAP Readiness The intent of the APQP PPAP Readiness review is to assure Supplier readiness for PPAP activities. 5 APQP - Launch The intent of the APQP Launch review is to close out and document trough corrective actions any open action item with Supplier. Also to provide feedback on Performance and Lessons Learned during Project Implementation.

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Supplier APQP Workbook

Definitions / Acronyms AIAG APQP BOM CC COTS DFMEA DOE DVP&R FMEA Key Components MSA Non Key Components P.I.P.C. % P.I.S.T. % PFMEA PPAP PSW QFD SC SDE SOP SPC WPDP

Automotive Industry Action Group (www.aiag.org) Advanced Product Quality Planning Bill of Material Critical Characteristic Custom of the Shelf, components that are supplier design responsibility and commonly available Design Failure Mode and Effects Analysis Design of Experiments Design Verification Plan and Report Failure Mode and Effects Analysis Components identified as Critical due to the complexity, cost and Lead Time during project development activities Measurement Systems Analysis Custom components non critical due to the complexity, cost and Lead time during project development activities Percentage of Inspection points that are Process Capable Percentage of Inspection points that Satisfy Tolerance Process Failure Mode and Effects Analysis Production Part Approval Parts Submission Warrant Quality Function Deployment Significant Characteristics Supplier Development Engineer Start of Production Statistical Process Control Westport Product Development Process

References ISO 9001 ISO/TS 16949 AIAG (http://www.aiag.org) Advanced Product Quality Planning and Control Plan, APQP Production Part Approval Process, PPAP Statistical Process Control, SPC Potential Failure Mode and Effects Analysis, FMEA Measurement Systems Analysis, MSA WPDP - Westport Product Development Process

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Fundamentals-Introduction

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Supplier APQP Workbook

WPDP Stages, Gates and Timeline


STAGE 0: CONCEPT DEFINITION

CUSTOMER, STATUTORY AND REGULATORY REQUIREMENTS

STAGE 1: PLAN AND DEFINE PROGRAM

GATE 0 Concept Initiation / Approval


Design Review

STAGE 2: STAGE 3: STAGE 4: STAGE 5: PRODUCT DESIGN AND PROCESS DESIGN AND PRODUCT AND PROCESS FEEDBACK, ASSESSMENT AND DEVELOPMENT DEVELOPMENT VALIDATION CORRECTIVE ACTION VERIFICATION VERIFICATION GATE 2 GATE 5 GATE 1 GATE 3 GATE 4 Alpha Build Program close Program Beta Build - Pilot Launch Initiation Prototype Initiation / out Initiation / Approval Initiation / / Approval Approval Approval Contract Design Verified
D Pre-Alpha Build E Level HW

Charter

Process Verified
L

Promotion Drawing Level

D
Alpha Build D Level HW

P Pre-Launch L Level HW

Product & Process Validated

Sign off
Customer SOP

Customers Satisfied

PLANNING

PPAP Run P Level HW

PRODUCT DESIGN AND DEVELOPMENT PROCESS DESIGN AND DEVELOPMENT PRODUCT AND PROCESS VALIDATION PRODUCTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

QUA LEG FINA CUST SUPPLY MFG ENGINE SALES & PROG. LITY AL & NCE OMER CHAIN ENG. ERING MARKET MGMT. COM CARE DEV

Finalize Contract, Lead & Manage Program

Lead & Manage Program

Assign Core Team, Build Business Case & Charter

Refine Market Assessment & Customer Requirements & Engage OEMs

Refine Customer Requirements & Work with OEMs Design & Verify Against Specifications Through Analysis and /or Engineering Prototypes Install Mfg Processes.Control Plan. Build Alpha Prototypes. Supplier Development Plan Defined Proto-Pdn. / Supppliers APQP started

Validate Customer Reqs. & Work with OEMs

Set Pricing, Create Market Introduction Plan & Field Sales Strategy Build & Validate Production Intent Product & Processes (Beta Build) Validate Operations Process Readiness Supplier Readiness Suppliers PPAP Complete

Choose Architecture and Preliminary Design & Modeling

Build & Verify Design Against Specifications (Alpha Build)

Mfg Plan & Identify Special Process Char.

Phase Order Equipment and Prepare Facilities Supplier Process Development Suppliers PPAP readiness

Production

Strategic Sourcing Requirements

Supplier Launch & Feedback

Plan Customer Care

Develop Service Infrastructure, Tools, Information & Training. Conduct Alpha Field Trials.

Validate Service Infrastructure, Tools, Information & Training. Conduct Beta Field Trials

Complete Financial & Funding Assessment

Project Budget & Finacial Business Case Tracking

PLIA NCE

Assess Legal or Regulatory Risks

Facilitate & Continuous Improvement

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Supplier APQP Workbook

APQP Status Report Form


Supplier: Location: Design Responsibility: Date: Part No.: Part Description: Rev. No.: 00 APQP Revision: Contact Directory Team Members 01 02 03 04 05

Company

Title

phone

email

APQP Level: APQP Timeline Milestones 1 APQP - Kick-Off 2 APQP - Product Design Feasibility signed (refer to 'Feasibility' tab) 3 APQP - Process Design 4 APQP - PPAP Readiness 5 APQP - Launch Total: Delivery Date Due Date Completion Date

Reason for APQP:

Progress in % 0% 0% 0% 0% 0% 0%

Status G/Y/R

Venue

Comments

Build Level 'E' - Pre-Alpha Prototype 'D' - Alpha Prototype 'L' - Pre-launch/Beta PPAP Parts 'P' - Production Run Parts PPAP Level:

Qty

Promotion Dates

(refer to 'PPAP Checklist' tab)

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Status Report Form

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Supplier APQP Workbook

APQP Status Report Form / Open Issues - Task List


Date # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Issues and Actions Responsible Due revised Due Completed Status G/Y/R Comments / Observations

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Status Report Form Open Issues

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Supplier APQP Workbook

1 Kick-Off Checklist

# Questions Has the contact directory been completed with Westport & Supplier stakeholders from all functions? Is the NDA (Nondisclosure Agreement) signed? Was a complete offer (including tool costs, parts price, transport and packaging, lead times, etc) submitted to Westport? Are all APQP reviews planned and do they match component milestones? Are there sufficient personnel identified to cover all APQP activities (e.g. engineering testing, Control plan requirements, problem solving ,)? Have the main Westport project milestones been communicated to the supplier (drawing release/ APQP reviews/ Prototype builds/tooling release/PPAP/ SOP)? Are they included in the APQP time plan?

Status

Person Responsible

Due Date

Completion Date

Comments

1 2 3 4 5

7 Is there an action plan for any critical path issues? 8 9 10 11 12 13 14 15 Has supplier got from Westport the latest version of the Technical Requirements and/or functional Specifications? Were the forecasted production and service volumes communicated? Is the supplier aware of Westport APQP, PPAP and Quality instructions? Is forecasted volume for prototypes, pre-production and serial production communicated to the supplier? Does the supplier get all necessary inputs from Westport? If no, list the missing elements. If the project requires new equipment and/or new tooling, is there a preliminary list of new equipment and/or new tooling? Is a preliminary BOM (Bill of material) for sub-contracted parts available? Does the supplier have a preliminary list of tier 2 suppliers?

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1 Kick-Off

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Supplier APQP Workbook

1 Kick-Off Checklist

# Questions Are the intended tier 2 Suppliers in compliance with at least ISO 9001? Will the supplier perform a APQP with tier 2 suppliers? Will the supplier perform a APQP for own production parts (e.g. major assembly)? Does the supplier have a traceability process related to special characteristics (ISO9001 7.3.2.1)? Does the supplier have a preliminary list of Special Characteristics? Has the supplier reviewed the technical data and signed the Feasibility Commitment? Has the supplier capacity to provide DFMEA using AIAG FMEA Reference Manual? Does the supplier have an appropriate Design/Process Change System that ensures traceability of every change? Has the supplier reviewed the technical specifications for any required in-process testing (e.g. leakage testing)? Has the supplier evaluated if there are any in-process testing needed based on his experience? Do you have included in your investment plan equipment related to 'in-process' testing? Is there an appropriate Lot Traceability system? Does the supplier have IMDS submission capabilities? Does the supplier have the capacity to provide robust Control plan using AIAG APQP Reference Manual and/or equivalent? Does the supplier understand the requirements for PPAP per AIAG requirements? Which PPAP Level is required? Please specify on Status Report Form. And is the supplier fully aware of the acceptance criteria for PPAP? Total yes: Total no: Total n/a: Progress:

Status

Person Responsible

Due Date

Completion Date

Comments

16 17 18 19 20 21 22 23

24 25 26 27 28 29 30 31

0 0 0 0%

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1 Kick-Off

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Supplier APQP Workbook

Product Design
Person Responsible Completion Date

# Questions Suppliers with Design/Development responsibility only Was the SFMEA (System FMEA) and/or DFMEA prepared 1 using the AIAG Failure Mode and Effects Analysis (FMEA) reference manual? Have historical campaign and warranty data been 2 reviewed? 3 Have similar part SFMEA / DFMEAs been considered? Does the SFMEA / DFMEA identify Special 4 Characteristics? Have design characteristics that affect high risk priority 5 failure modes been identified? Have appropriate corrective actions been assigned to high 6 risk priority numbers? Have appropriate corrective actions been assigned to high 7 severity numbers? Have risk priorities been revised when corrective actions 8 have been completed and verified? 9 Are design reviews planned? Do the design reviews include design targets, quality 10 targets, reliability, costs and due dates? 11 Has Design of Experiments (DoE) been considered? 12 Has DFMEA been completed? 13 Has the Design Verification Plan been considered? Are all specified tests, methods, equipment and 14 acceptance criteria clearly defined and understood? 15 Have Special Characteristics been selected? 16 Is Bill of Material complete? 17 Was a DFMEA review performed by Westport? All Suppliers ('E'-parts / Pre-Alpha) Are drawings and specifications available for Pre-Alpha 18 Prototypes ('E'-parts)? Was a Pre-Alpha Prototype Control Plan prepared? ('E'19 parts) Was the Pre-Alpha Prototype Control Plan communicated 20 and approved by Westport? ('E'-parts)

Status

Due Date

Comments

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Supplier APQP Workbook

Product Design
Person Responsible Completion Date

# Questions Are all special product/process characteristics included in the Pre-Alpha Prototype Control Plan? ('E'-parts) Are gages and test equipment available as required by the 22 Pre-Alpha Prototype Control Plan? ('E'-parts) Are gage methods compatible between supplier and 23 Westport? All Suppliers ('D'-parts / Alpha) Are drawings and specifications available for Alpha 24 Prototypes ('D'-parts)? 21 25 Was a Alpha Prototype Control Plan prepared? ('D'-parts) 26 27 28 29 30 31 Was the Alpha Prototype Control Plan communicated and approved by Westport? ('D'-parts) Are all special product/process characteristics included in the Alpha Prototype Control Plan? ('D'-parts) Are gages and test equipment available as required by the Alpha Prototype Control Plan? ('D'-parts) Are gage methods compatible between supplier and Westport? Does the process flow chart illustrate the sequence of production and inspection? Does the supplier perform capability studies for the existing processes? And are the machine/process capabilities for new equipment forecasted? Total yes: Total no: Total n/a: Progress:

Status

Due Date

Comments

0 0 0 0%

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Supplier APQP Workbook

Team Feasibility Commitment / Supplier Design Review


Supplier: Location: Date: Part No.: Part Name: 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 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? Is the product adequately defined to enable feasible measuring? Can product be manufactured without incurring any unusual: - Costs for capital equipment? - Costs for tooling? - 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: - Are the processes in control and stable? - Are Cpk's greater than 1.67? 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 #

> 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. Corrective Actions / Resolution Plan

Issues / Comments / Risks

Supplier Sign-Offs: (there is minimum a sign off from Engineering, Quality and Production required) Name Title Date

Signature

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Feasibility

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Supplier APQP Workbook

Process Design
Person Responsible Completion Date

# Questions Drawings, Feasibility and SPC characteristics Are drawings and specifications available for Pre1 Launch/Production parts ('L/P'-parts)? 2 3 Has the supplier reviewed the technical data and signed the Feasibility Commitment? Are any updates required?

Status

Due Date

Comments

Have the SPC characteristics been defined/updated and do they comply with the current drawing? If necessary, have SPC characteristics been 4 communicated to tier 2 suppliers? Can all dimensions and tolerances be manufactured and 5 monitored in a process capable manner? Are all necessary standards and Westport specifications 6 available and released? Process FMEA Was the Process FMEA prepared by a cross functional 7 team? Have all operations including subcontracted, or outsourced 8 processes and services been considered in the Process FMEA? Have all operations affecting customer requirements including fit, function, durability, governmental regulations 9 and safety been identified and listed sequentially in the Process FMEA? New Equipment and Tooling Have lists been prepared identifying the progress of new 10 equipment, tooling, test equipment? Have orders been placed for new equipment, tooling, test 11 equipment? 12 13 Have lists been prepared identifying the progress of new equipment, tooling, test equipment at tier 2 suppliers? Have orders been placed for new equipment, tooling, test equipment at tier 2 suppliers?

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Supplier APQP Workbook

Process Design
Person Responsible Completion Date

# Questions Process Flow Chart Has a process flow chart been developed and it illustrates 14 the entire process from receiving through shipping, including outside processes and services? Have lean concepts been applied in considering material 15 flow? Control Plan 16 17 Were DFMEA, and PFMEA used to prepare the control plan, to identify specific characteristics that may be critical?

Status

Due Date

Comments

Is the flow chart keyed to product and process checks in the control plan and PFMEA? Is each operation provided with process instructions that 18 are keyed to the control plan? Are all special product/process characteristics included in 19 the control plan? Were DFMEA, and PFMEA used to prepare the control 20 plan? 21 If required, has the customer approved the control plan? Are gage methods compatible between supplier and 22 customer? Resources, Training, Operator and Inspection Instructions Are there sufficient qualified personnel identified to cover: - Control Plan requirements? - Layout inspections? 23 - Engineering performance testing? - Problem reaction and resolution analysis? - Quality liaison with Westport? - Quality liaison with tier 2 suppliers? Is the skill matrix for manufacturing operations available 24 and updated? Are standard operator instructions accessible at each work 25 station? 26 Do operator instructions include pictures and diagrams?

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Supplier APQP Workbook

Process Design
Person Responsible Completion Date

# Questions Were operator/team leaders involved in developing standard operator instructions? Do inspection instructions include: Easily understood engineering performance specifications?

Status

Due Date

Comments

27 28

Do inspection instructions include: - Test frequencies? 29 - Sample sizes? - Reaction plans? - Documentation requirements? Are visual aids: - Appropriate, easily understood and legible? - Available? 30 - Accessible? - Approved? - Dated and current? Are all operators trained on the operator and inspections 31 instructions? Is there an emergency plan? (e.g. for key machine or tooling breakdown; if the company is in a tornado, 32 earthquake, flood area, etc.; can the supplier be reached after hours for urgent (replacement) orders; etc) Equipment Feasibility and Preliminary Process Capability Studies Will a preliminary capability study be conducted at the 33 tooling and/or equipment manufacturer? Will preliminary process capability studies be run at the 34 processing plant? Has test equipment feasibility and accuracy been 35 established? Is a preventive maintenance plan complete for equipment 36 and tooling? Are setup instructions for new equipment and tooling 37 complete and understandable?

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Supplier APQP Workbook

Process Design
Person Responsible Completion Date

# Questions Capacity Does the manufacturing equipment have sufficient 38 capacity to handle forecasted production and service volumes? 39 Is testing capacity sufficient to provide adequate testing? 40 Can the forecasted production volumes be met? 41 Can all dates per project schedule be met? Total yes: Total no: Total n/a: Progress:

Status

Due Date

Comments

0 0 0 0%

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Supplier APQP Workbook

4 PPAP Readiness

# Questions 1 Is the APQP and project time plan updated? 2 Are risks associated to the project identified and updated? 3 4 5 6 7 8 9 10 11 12 13 Are the final Process Flow, PFMEA, Floor Plan and Control Plan available? Are the final Gauges, Tooling and Equipment ordered and will arrive on time? Is the final Measurement System Analysis planned and agreed upon? Has training been completed for new processes/machines? Is the skill matrix updated and available? Does the Supplier have a Production Capacity and Ramp up Plan? Is the Run at Rate scheduled? Is the process and flow for non conforming product adequate to prevent use of these parts in production? Has packaging been considered and approved by Westport if applicable? Have all special characteristics been identified in the future process and are these special characteristics identified in the Control Plan? Has the PPAP Checklist been reviewed and agreed upon by Supplier and Westport?

Status

Person Responsible

Due Date

Completion Date

Comments

14 Are Tier 2 PPAP's completed without any open deviations? 15 16 17 18 19 Is there an action plan for any open deviations on Tier 2 PPAP's? Are Tier 2 capacities secured according to Supplier and Westport capacity planning? Has material data sheet been submitted in the IMDS system? Has material data sheet in the IMDS system been accepted by Westport? Is Supplier ready for PPAP submission on schedule? Total yes: Total no: Total n/a: Progress:

0 0 0 0%

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4 PPAP Readiness

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Supplier APQP Workbook

Launch
Person Responsible Completion Date

# Questions 1 Is the PSW completed according to PPAP manual? 2 Is there an action plan for remaining PPAP deviations? Has the supplier informed Westport about any changes 3 that have occurred after PPAP submission? (If there were changes, please note in the comment column.) If there were any changes, is the new PPAP submission 4 scheduled? Has the Run at Rate been performed and the results in 5 terms of quality and capacity are acceptable? Have process capabilities been confirmed and are 6 acceptable after the Run at Rate? Has the supplier performed a final process audit of the final 7 serial process? Is there an action plan for deviations found during the final 8 process audit and/or corrective actions already implemented? Were PPAP parts shipped in the approved packaging? 9 Were there any problems with the packaging? 10 Is Supplier ready for SOP? Total yes: Total no: Total n/a: Progress:

Status

Due Date

Comments

0 0 0 0%

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5 Launch

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Supplier APQP Workbook

PPAP Submission Checklist


All documents must be submitted in Westport accepted format

SUPPLIER PART NUMBER PART DESCRIPTION PREPARED BY

0 #VALUE! #VALUE! DATE


REVISION

#VALUE! Level 1 Level 2 Level 3 Level 4 Level 5

SUBMISSION LEVEL (choose from drop down menu)

Submission Element 1. Design Record


Print/Drawing or Specification

Submission Requirement

Initial for Westport Compliance

Approved

Rejected

Comments / Actions

2. Engineering Change Notice


Approved SRDC

3. Customer Engineering Approval


Approved Westport signature on supplier drawing

4. Design FMEA
For supplier designed part, if required by Westport

5. Process Flow Diagram


Manufacturing process flow for part

6. Process FMEA
Manufacturing analysis for product line

7. Control Plan
Required for specific manufacturing plan of part

8. MSA
Necessary when process capability is required

9. Dimensional Results
Record of inspection to print features

10. Material / Performance Result


For specific test results or certification as instructed on print

11. Initial Process Study


Required if classified characteristics are noted on print

12. Qualified Laboratory Documentation


As defined by Westport

13. Appearance Approval Report


When required by Westport

14. Sample Production Parts


Production representative sample

15. Master Sample


Retain for 30 days after PPAP Approval

16. Checking Aids


Document special gauges or fixtures to validate sample

17. Record of Compliance


For Westport specific requirements.

18. Part Submission Warrant


Approved Westport version required

Checklist Issue and Receipt Sign-offs


Print Name Issued By: (Westport SDE) Supplier Receipt Confirmation and Agreement Reviewed By: (Westport SDE) Signature Date

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PPAP Checklist

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APQP Workbook

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DATA

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