Académique Documents
Professionnel Documents
Culture Documents
Planning)
Supplier Version
• Background
APQP - Key Features when considering GPDS
JLR & Supply Base Integration
Process overview
PMST: Key Deliverables
Contents (continued)
Ongoing Communication of
requirements, changes, effects,
issues, solutions, re-planning
= PMST Core Business
Supplemented by STA Site
activities ~ (Priority Supplier
Manufacturing sites)
APQP: Approach
Mail box
Supplier
Sourcing
Begins
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Priority Buyer, STA Site Engineer and representatives from other JLR
Element Summary Suppliers
Selected functions as required
Report - All Suppliers
Deliverables: Completion Cross-
vs Due GPDS Milestone
Functional Resolve Open Issues
Teams Formed
Mail box
Supplier
Sourcing
Begins
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Priority Buyer, STA Site Engineer and representatives from other JLR
Element Summary Suppliers
Selected functions as required
Report - All Suppliers
Deliverables: Completion Cross-
vs Due GPDS Milestone
Functional Resolve Open Issues
Teams Formed
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Supplier
Sourcing
Begins
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Priority Buyer, STA Site Engineer and representatives from other JLR
Suppliers
Selected functions as required
Cross-
Functional Resolve Open Issues
Teams Formed
Mail box
Supplier
Sourcing
Begins
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Priority Buyer, STA Site Engineer and representatives from other JLR
Element Summary Suppliers
Selected functions as required
Report - All Suppliers
Deliverables: Completion Cross-
vs Due GPDS Milestone
Functional Resolve Open Issues
Teams Formed
Pre APQP: Site STA <PA> 2. Required Supplier Commercial & Program Agreements Signed
objective is:
If STA Approves Non-Q1 <FDJ> 3. All Production Tool Orders Issued to Suppliers
Sourcing then there is a <PA> 4. Final Mix, Maximum Weekly Volume Communicated and Agreed
sound basis for viability.
2. Customer input requirements PD <PA> 5. Program Expectations Cascaded to Suppliers
5. Design/manufacturing reviews PD/STA <PP> 10. Quality Issues Closed and Effective
7. Subcontractor APQP status STA <FDJ> 12. Sub-supplier PPAP Timing Plan Completed
8. Facilities, Tools & Gauges STA <FDJ> 15. Facility and Tooling Timing Plan Completed
9. Prototype Control Plan PD <FDJ> 20. Prototype Build Control Plan Completed
10. Prototype Build PD <FDJ> 21. All Prototype Tool Orders Issued to Suppliers
12. Engineering Change PD <TT> 26. All JLR Engineering Changes Approved & Recognized by the
Supplier
13. Team Feasibility PD/STA <FDJ> 27. Design, Process, & Timing Feasibility Confirmation
14. Manufacturing Process Flow STA <PEC> 28. Final Process Flowchart Supports PPAP Phase 0 Event
15. PFMEA STA/PD <VP> 29. Final PFMEA Completed with Linkages
16. Measurement System Analysis STA <TT> 30. Gauge R&R Results <= 10% per PPAP Ford Customer Specifics
17. Qualified Laboratory Documents STA <TT> 31. Supplier Internal & External Laboratory Compliance
18. Checking Aids STA <TT> 32. Checking Aids Compliant With Part Specifications
19. Pre-Launch Control Plan STA <PEC> 33. Pre-Launch Control Plan Completed with Linkages
20. Operator Instructions STA <PEC> 34. Operator Process Instructions Completed
21. Packaging Specifications MP&L <TT> 35. Packaging Approval Process Completed
22. Production Trial Run STA <TT> 36. PPAP Phase 0 (Including Sub-suppliers) Completed
23. Production Control Plan STA <TT> 37. Production Control Plan Complete with Linkages
24. Initial Process Capability STA <TT> 38. Initial Process Capability Results (Ppk >= 1.67)
25. Dimensional Results STA <TT> 39. 100% of Required Measured Points within Tolerance
28. Bulk Material Requirements STA <TT> 46. Bulk Materials Checklist Included in PPAP Submission
29. Sample Product STA <TT> 47. Sample Product Produced with JLR Identification
31. Record of Compliance STA <TT> 49. JLR Specific Requirements Documented
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Teams Formed
UN: <PTCC>
Team Decision
to
Kick-Off UP: <PTCC>Evaluation
Evaluation + 90 Days Proceed
Evaluation Evaluation
Meetings #1 #2 #3 #4
to Run-
Begin At-Rate
Principles of Use:
• Completed by all NTEI Suppliers
• Submitted to JLR monthly after <PTCC>
• Consolidated automatically to produce rolled-up supplier
deliverables & readiness reports
Summary View (OFF) Click Here to Clear Entries Formatted to Print A4 (EU) Highlight Next Deliverable (ON) Import Previous APQP
APQP JLR Version 1 JLR Contact Information
Final
Current Milestone FDJ
FDJ
Assessment
Priority Site Select Vehicle PartitionUnderbody
Underbody Select Vehicle PMT Chassis
Chassis Supplier Contact Information
(Corporate Directory System ID)
Manufacturing Supplier Site Code: XXXXX Base Part Number: AC123456 Program Contact Name: AS MITH
Information
Program Name: RANGE ROVER Supplier Name: XXXXX Base Part Name: WIDGET Program Contact Phone: 0044 123456 Lead STA Site Engineer: DSNITH
Model Year: 2013 Location: XXXXX Total Number of Parts: 99 e-mail Address: ASMITH@SUPP Lead Buyer: ESMITH
APQP Current Date: 15/01/2010 Q1 Status: Y Y User Plant: JLR Plant Contact Name: BS MITH
DD-MMM-YY
Submission
Dates
Previous APQP Date: 18/11/2009 Q1 Score: 1000 Plant Contact Phone: 0044 234555 MP&L Analyst: FSMITH
email Address: BSMITH@SUPP Program Mailbox: APQPL405
Dates
DD-MMM-YY Actual Action Plan/
VPP Timing
Dates
DD-MMM-YY
1. Sourcing Decision
All Quality, Cost, Weight, and Functional (QCWF) targets have been reviewed, documented and
1 agreed as part of the Sourcing Agreement Process.
The Preliminary Engineering, Development & Testing (ED&T) budget has been defined in the
2 Sourcing Agreement.
Supplier agreement letter has been issued and the supplier manufacturing site has been
a) Sourcing Agreement 1 C
identified.
3 Cost model has been developed and agreed, including process to manage change control.
4 There are no outstanding issues on the Final ED&T budget and QCWF targets.
All required Supplier Commercial and Program Agreements (CPA) have been signed.
b) Commercial and 2 Note: UN and UP due 2 months before <PA>, PTO scale 1-4 due 1 month before <PTC>, PTO C
Program Agreement scale 5 and 6 due 2 months before <PA>.
3 All Production tooling orders have been issued to suppliers. C
Final Mix (estimated Take Rate), Average Production Weekly (APW) and Maximum Production
c) Volume and Mix 4 C
Weekly (MPW) have been communicated and agreed by the supplier via the SA/CPA document.
Supplier has received the Program Timing Dates for APQP requirements, Program Status
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
8 Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
Supplier has received applicable affordable cost targets, as they are defined for the Program,
9 including capacity and peak volumes.
Supplier has received and understood any related logistics and volume requirements (including
10 packaging concerns, density of containers and frequency of shipment).
Supplier has received all necessary information identified in the expectations of the Customer
5 Input Requirements element, to plan, design, manufacture and ship the product. C
APQP Assessment: Functionality
Functionality:
• The APQP Assessment uses Excel macros to function
properly.
• The user must always select ENABLE macros. Failure to
enable the macros will result in loss of functionality.
• The APQP assessment is designed for use with Excel 2003
and Excel 2007.
• Using previous versions of Excel will result in a loss of
functionality.
• For further guidance please refer to the APQP User Guide
APQP Assessment: Meeting cadence
Priority Suppliers:
• Submit the APQP Assessment monthly as required by the
STA programme team.
• Site STA to review the APQP Assessment with the rest of
the PMST prior to this monthly submission.
Non Priority Suppliers:
• Submit the APQP Assessment as per Priority Suppliers
• Send copy of APQP Assessment to STA and PD engineers
prior to submission to the JLR programme team
APQP Assessment -- Detail
31
Structure:
APQP
Elements The Element Status section
49
of the Assessment is
Deliverables structured in a hierarchy that
(minimum 1 includes:
per element)
Team QoE -- APQP Elements
215 -- Deliverables
Business Expectations Criteria -- Expectations
Summary View (OFF) Click Here to Clear Entries Formatted to Print A4 (EU) Highlight Next Deliverable (ON) Import Previous APQP
The suppliers will enter their
specific status ratings in this
APQP JLR Version 1 JLR Contact Information
Final
Current Milestone FDJ
FDJ
Assessment
Priority Site Select Vehicle PartitionUnderbody
Underbody Chassis
Select Vehicle PMT Chassis Supplier Contact Information
(Corporate Directory System ID)
Manufacturing Supplier Site Code: XXXXX Base Part Number: AC123456 Program Contact Name: AS MITH
Information
Program Name: RANGE ROVER Supplier Name: XXXXX Base Part Name: WIDGET Program Contact Phone: 0044 123456 Lead STA Site Engineer: DSNITH
Model Year: 2013 Location: XXXXX Total Number of Parts: 99 e-mail Address: ASMITH@SUPP Lead Buyer: ESMITH
APQP Current Date: 15/01/2010 Q1 Status: Y Y User Plant: JLR Plant Contact Name: BS MITH
DD-MMM-YY
Submission
Dates
Dates
DD-MMM-YY Actual Action Plan/
VPP Timing
Dates
DD-MMM-YY
1. Sourcing Decision
Supplier has received the Program Timing Dates for APQP requirements, Program Status
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
8 Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
Supplier has received applicable affordable cost targets, as they are defined for the Program,
9 including capacity and peak volumes.
Supplier has received and understood any related logistics and volume requirements (including
10 packaging concerns, density of containers and frequency of shipment).
Supplier has received all necessary information identified in the expectations of the Customer
5 Input Requirements element, to plan, design, manufacture and ship the product. C
APQP Assessment -- Detail
Program Name: RANGE ROVER Supplier Name: XXXXX Base Part Name: WIDGET Program Contact Phone: 0044 123456 Lead STA Site Engineer: DSNITH
Model Year: 2013 Location: XXXXX Total Number of Parts: 99 e-mail Address: ASMITH@SUPP Lead Buyer: ESMITH
APQP Current Date: 15/01/2010 Q1 Status: Y Y User Plant: JLR Plant Contact Name: BSMITH
DD-MMM-YY
Submission
Dates
Previous APQP Date: 18/11/2009 Q1 Score: 1000 Plant Contact Phone: 0044 234555 MP&L Analyst: FSMITH
email Address: BSMITH@SUPP Program Mailbox: APQPL405
Dates
DD-MMM-YY Actual Action Plan/
VPP Timing
Dates
DD-MMM-YY
1. Sourcing Decision
All Quality, Cost, Weight, and Functional (QCWF) targets have been reviewed, documented and
1 agreed as part of the Sourcing Agreement Process.
The Preliminary Engineering, Development & Testing (ED&T) budget has been defined in the
2 Sourcing Agreement.
Supplier agreement letter has been issued and the supplier manufacturing site has been
a) Sourcing Agreement 1 C
identified.
3 Cost model has been developed and agreed, including process to manage change control.
4 There are no outstanding issues on the Final ED&T budget and QCWF targets.
All required Supplier Commercial and Program Agreements (CPA) have been signed.
b) Commercial and 2 Note: UN and UP due 2 months before <PA>, PTO scale 1-4 due 1 month before <PTC>, PTO C
Program Agreement scale 5 and 6 due 2 months before <PA>.
3 All Production tooling orders have been issued to suppliers. C
Final Mix (estimated Take Rate), Average Production Weekly (APW) and Maximum Production
c) Volume and Mix 4 C
Weekly (MPW) have been communicated and agreed by the supplier via the SA/CPA document.
Supplier has received the Program Timing Dates for APQP requirements, Program Status
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
8 Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
Supplier has received applicable affordable cost targets, as they are defined for the Program,
9 including capacity and peak volumes.
Supplier has received and understood any related logistics and volume requirements (including
10 packaging concerns, density of containers and frequency of shipment).
Supplier has received all necessary information identified in the expectations of the Customer
5 Input Requirements element, to plan, design, manufacture and ship the product. C
APQP Assessment -- Detail
1. Header Section
Summary View (OFF) Click Here to Clear Entries Formatted to Print A4 (EU) Highlight Next Deliverable (ON) Import Previous APQP
APQP JLR Version 1 JLR Contact Information
Final
Current Milestone FDJ
FDJ
Assessment
Priority Site Select Vehicle PartitionUnderbody
Underbody Chassis
Select Vehicle PMT Chassis Supplier Contact Information
(Corporate Directory System ID)
Manufacturing Supplier Site Code: XXXXX Base Part Number: AC123456 Program Contact Name: ASMITH
Information
Program Name: RANGE ROVER Supplier Name: XXXXX Base Part Name: WIDGET Program Contact Phone: 0044 123456 Lead STA Site Engineer: DSNITH
Model Year: 2013 Location: XXXXX Total Number of Parts: 99 e-mail Address: ASMITH@SUPP Lead Buyer: ESMITH
APQP Current Date: 15/01/2010 Q1 Status: Y Y User Plant: JLR Plant Contact Name: BSMITH
DD-MMM-YY
Submission
Dates
Previous APQP Date: 18/11/2009 Q1 Score: 1000 Plant Contact Phone: 0044 234555 MP&L Analyst: FSMITH
email Address: BSMITH@SUPP Program Mailbox: APQPL405
Dates
DD-MMM-YY Actual Action Plan/
VPP Timing
Planned Completion Counter
Completion Engineering Milestones M-1DJ AA1 AA2 FDJ PEC FEC Action Plan/
Evidence Dates Action Plan/ Measure
ELEMENT Date Expectations / Deliverables Dates
Counter Measure
(Metric) Counter Measure Description Date
05-Feb-10 05-Feb-11 Responsibility
DD-MMM-YY DD-MMM-YY
MP1 DD-MMM-YY DD-MMM-YY
Builds UNV0 UNV1 UNV2 UPV0 UPV1 UPV2 TT MRD PP MRD
MRD
MP2
Dates
DD-MMM-YY
1. Sourcing Decision
All Quality, Cost, Weight, and Functional (QCWF) targets have been reviewed, documented and
1 agreed as part of the Sourcing Agreement Process.
The Preliminary Engineering, Development & Testing (ED&T) budget has been defined in the
2 Sourcing Agreement.
Supplier agreement letter has been issued and the supplier manufacturing site has been
a) Sourcing Agreement 1 C
identified.
3 Cost model has been developed and agreed, including process to manage change control.
There are no outstanding issues on the Final ED&T budget and QCWF targets.
The header section of the Assessment provides general information about part,
4
All required Supplier Commercial and Program Agreements (CPA) have been signed.
b) Commercial and 2 Note: UN and UP due 2 months before <PA>, PTO scale 1-4 due 1 month before <PTC>, PTO C
Program Agreement scale 5 and 6 due 2 months before <PA>.
There are also selection boxes that indicate Priority/Non-Priority, GPDS Vehicle
(MP&L) and others as appropriate.
Supplier has received specifications, as they become available, to understand Product
6 Assumptions, Functional Performance, Dimensions, Weights, Materials, and Craftsmanship
requirements. Requirements for service parts (if applicable) have also been cascaded.
Partition (Powertrain – PT, Underbody – UN, Upperbody – UP), and PMT. These
Supplier has received Reliability and Quality Goals including Functional Performance Specs, 10
7 yr/150 mileage Useful Life Reliability Initiative (ULRI) Targets, Warranty Targets, and Incoming
Quality Targets (PPM, etc.).
Supplier has received the Program Timing Dates for APQP requirements, Program Status
selection boxes are important because they are required for management reports, and
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
8 Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
they will display the proper rows to reflect differences in UP and UN timing, for
Supplier has received applicable affordable cost targets, as they are defined for the Program,
9 including capacity and peak volumes.
Supplier has received and understood any related logistics and volume requirements (including
10 packaging concerns, density of containers and frequency of shipment).
example.
Supplier has received all necessary information identified in the expectations of the Customer
5 Input Requirements element, to plan, design, manufacture and ship the product. C
Expectation Number
Deliverable Number
Dates
DD-MMM-YY
VPP Timing
Planned
Completion Engineering Milestones M-1DJ
ELEMENT Date Expectations / Deliverables Dates
DD-MMM-YY DD-MMM-YY
Builds UNV0 UNV1 UNV2 UPV0
Dates
DD-MMM-YY
11. Drawing & Specifications / Design Records
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
86 following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
Identify any specified requirements and specifications that cannot be evaluated using known
87 inspection techniques and request appropriate adjustments from engineering.
24 Design Styling is completed
Plan to complete P-Authority Release by FDJ + 4 weeks.
25 NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
12. Engineering Change Document
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
88 specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
All Jaguar Land Rover engineering changes have been recorded, approved and recognised on
26 an authorised engineering change document.
Element:
Expectation Number
Deliverable Number
Dates
DD-MMM-YY
VPP Timing
Planned
Completion Engineering Milestones M-1DJ
ELEMENT Date Expectations / Deliverables Dates
DD-MMM-YY DD-MMM-YY
Builds UNV0 UNV1 UNV2 UPV0
Dates
DD-MMM-YY
11. Drawing & Specifications / Design Records
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
86 following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
Identify any specified requirements and specifications that cannot be evaluated using known
87 inspection techniques and request appropriate adjustments from engineering.
24 Design Styling is completed
Plan to complete P-Authority Release by FDJ + 4 weeks.
25 NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
12. Engineering Change Document
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
88 specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
All Jaguar Land Rover engineering changes have been recorded, approved and recognised on
26 an authorised engineering change document.
Deliverables are the metrics used to define the status (RED/YELLOW/GREEN/COMPLETE) of the
individual 31 elements.
There is at least one Deliverable for each element, but there can be multiple deliverables for each
element. As noted previously, there are a total of 49 Deliverables.
Deliverables are intended to reflect, where possible, quantifiable evidence of element success or
completion. Deliverables can reflect key in-process metrics like Cpk or OEE, for example.
APQP Assessment -- Detail
Expectation Number
Deliverable Number
Dates
DD-MMM-YY
VPP Timing
Planned
Completion Engineering Milestones M-1DJ
ELEMENT Date Expectations / Deliverables Dates
DD-MMM-YY DD-MMM-YY
Builds UNV0 UNV1 UNV2 UPV0
Dates
DD-MMM-YY
11. Drawing & Specifications / Design Records
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
86 following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
Identify any specified requirements and specifications that cannot be evaluated using known
87 inspection techniques and request appropriate adjustments from engineering.
24 Design Styling is completed
Plan to complete P-Authority Release by FDJ + 4 weeks.
25 NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
12. Engineering Change Document
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
88 specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
All Jaguar Land Rover engineering changes have been recorded, approved and recognised on
26 an authorised engineering change document.
All 49 Deliverables are required to be rated with every submission of the Assessment
Against the program milestones, Deliverables will show two colour schemes:
• Light Grey With No Box – Forecast Period (activity is not expected in this time period, but the
supplier must enter a rating to show whether or not they forecast risk to the deliverable completion
in the future.
• Dark Grey With Black Box – Deliverable Start & End Points (activity is expected to begin and end
between these milestones)
APQP Assessment -- Detail
Expectation Number
Deliverable Number
Dates
09-Sep-09 14-Sep-09 16-Nov-09
DD-MMM-YY
VPP Timing
Planned
Completion Engineering Milestones M-1DJ AA1 AA2 FDJ
ELEMENT Date Expectations / Deliverables Dates 05-Feb-10
DD-MMM-YY DD-MMM-YY
Builds UNV0 UNV1 UNV2 UPV0 UPV1 UPV2
Dates
10-Sep-09 11-Sep-09 12-Sep-09 15-Sep-09
DD-MMM-YY
11. Drawing & Specifications / Design Records
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
86 following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
Identify any specified requirements and specifications that cannot be evaluated using known
87 inspection techniques and request appropriate adjustments from engineering.
24 Design Styling is completed
Plan to complete P-Authority Release by FDJ + 4 weeks.
25 NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO). G G G G G G G C
Confirm with the JLR PD Engineer that the release plan supports program requirements.
Example:
This deliverable is rated GREEN in the Forecast period denoting there was no expected risk to
completion by FDJ.
The Deliverable Start & End point spans <PA> to <FDJ>. The <PA> milestone is rated GREEN, and the
<FDJ> milestone is rated COMPLETE. Per GPDS convention, the Deliverable end point can only be
rated RED (if not finished) or COMPLETE (if finished).
APQP Assessment -- Detail
Expectation Number
Deliverable Number
Dates
09-Sep-09 14-Sep-09 16-Nov-09
DD-MMM-YY
VPP Timing
Planned
Completion Engineering Milestones M-1DJ AA1 AA2 FDJ
ELEMENT Date Expectations / Deliverables Dates
05-Feb-10
DD-MMM-YY DD-MMM-YY
Builds UNV0 UNV1 UNV2 UPV0 UPV1 UPV2
Dates
10-Sep-09 11-Sep-09 12-Sep-09 15-Sep-09
DD-MMM-YY
11. Drawing & Specifications / Design Records
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
86 following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
Identify any specified requirements and specifications that cannot be evaluated using known
87 inspection techniques and request appropriate adjustments from engineering.
24 Design Styling is completed
Plan to complete P-Authority Release by FDJ + 4 weeks.
25 NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO). G G G G G G G C
Confirm with the JLR PD Engineer that the release plan supports program requirements.
Expectations are guidelines used to assist team members in the successful completion of the
elements, and where applicable, help rate completion of the related deliverables.
While expectations can be rated RED/YELLOW/GREEN/COMPLETE, they will not drive the element
rating – only deliverables are rolled-up to drive element ratings.
The ratings for expectations are intended only for internal use and communication.
Expectation Number
Deliverable Number
Dates
09-Sep-09 14-Sep-09 16-Nov-09
DD-MMM-YY
VPP Timing
Planned
Completion Engineering Milestones M-1DJ AA1 AA2 FDJ
ELEMENT Date Expectations / Deliverables Dates
05-Feb-10
DD-MMM-YY DD-MMM-YY
Builds UNV0 UNV1 UNV2 UPV0 UPV1 UPV2
Dates
10-Sep-09 11-Sep-09 12-Sep-09 15-Sep-09
DD-MMM-YY
11. Drawing & Specifications / Design Records
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
86 following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and Y Y G C
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
Identify any specified requirements and specifications that cannot be evaluated using known
87 inspection techniques and request appropriate adjustments from engineering. Y Y G C
24 Design Styling is completed G G G C
Plan to complete P-Authority Release by FDJ + 4 weeks.
25 NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO). G G G G G G G C
Confirm with the JLR PD Engineer that the release plan supports program requirements.
12. Engineering Change Document
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
88 specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
Example:
These Expectations were rated YELLOW at <PTC> and AA1 showing a potential risk.
3. Summary Section
This part of the Assessment is intended to summarise the element status for the entire document.
There are 4 parts to the summary:
1. Current Milestone Deliverable Status
2. Forecast Milestone Deliverable Status
3. Phased PPAP Element Dates
4. Supplier Evaluation Summary (Priority sites only)
APQP Assessment -- Detail
3. Summary Section
Indicates the status for only those elements with deliverables required to be completed by the
currently assessed milestone. These fields are automatically generated based upon input in the
Element Status.
The one exception are the words for the Action Plan Summary – these must be manually entered and
should be limited to the Key Escalation Issues, and not made up from a cut
and paste of the Element status section.
APQP Assessment -- Detail
3. Summary Section
Indicates the status of remaining deliverables not yet required for completion at a given milestone. The
majority of these fields are automatically generated based upon input in the Element Status. The
Action Plan Summary fields must be manually entered.
This provides a forward looking view of future deliverables for use by the team.
APQP Assessment -- Detail
3. Summary Section
A summary of PPAP dates outline in the Required for Priority suppliers only. The team
Element Status. The dates are automatically manually tracks planned and actual visit dates.
populated from the deliverables, while Build The data is rolled up on Element Summary
Support Plans must be manually entered Report.
APQP: Summary of Deliverable Rating Criteria
Summary of Deliverable Rating Criteria
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Supplier
Sourcing
Begins
Once sourcing is complete, the STA Programme
Lead and the PD Programme Lead will work with the
Priority STA Site Managers & Engineers, and PD
Suppliers
Selected Programme Leaders & PMST Leaders to complete
the Selection of “Priority” suppliers for the
Cross- Resolve Open Issues
Functional programme.
Teams Formed
A specific risk model is used to guide the Priority
Decision
Team
Kick-Off
suppliers.
Evaluation Evaluation to Evaluation Evaluation
Proceed #4
Meetings #1 #2 #3
to Run-
Begin At-Rate
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Supplier
Sourcing
Begins The STA and PD Programme leads will notify the
Priority appropriate PD Engineers, Buyers, and STA Site
Suppliers
Selected Engineers, that their suppliers are designated as
Cross-
Priority for a given programme. This notification
Functional will include specific timing and reporting
Resolve Open Issues
Teams Formed
requirements for the programme.
Team Decision
Kick-Off Evaluation Evaluation to Evaluation Evaluation
Proceed #4
Meetings #1 #2 #3
to Run-
Begin At-Rate
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Supplier
Sourcing
Begins
Priority
Prior to the Evaluations, the cross-functional JLR
Suppliers team members will meet with their supplier team
Selected
to review programme expectations and begin the
Cross- preparations for siteResolve
visits.Open Issues
Functional
Teams Formed
This is called the “Kick-Off” meeting.
Team Decision
On-Site to On-Site On-Site
Kick-Off Evaluation Evaluation
Evaluation Proceed Evaluation
Meetings #1 to Run- #4
#2 #3
Begin At-Rate
Participants:
Lead: PD Engineer
Support: STA Site Engineer, Buyer
Location:
JLR facility, supplier facility, or teleconference (according to team preference). Meetings will typically
last 2 – 3 hours.
Evaluation #1
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Team Decision
Evaluation Evaluation to Evaluation Evaluation
Kick-Off Proceed
Meetings #1 #2 #3 #4
to Run-
Begin At-Rate
Purpose:
• Failure Mode Avoidance through detailed FMEA and Control Plan reviews:
• Feasibility & actions to resolve by FDJ
• Manufacturing Planning
• Capacity Planning
Note: Actual review timing will be dependant upon the specific needs of the component and the program.
Participants:
Why? Supplier confirming that PD has communicated the design, that the supplier
understands the design and that planned process is capable of producing the
design, and that no design changes will be requested to solve manufacturing
problems after FDJ. PD & STA confirm this within JLR.
If issues are found that have no known solution then these should be escalated to
JLR STA & PD and an AIMS raised
Output Responsibility
2 All
Agreement on Failure Mode Avoidance Strategy (All DFMEA’s up to
date & Agreement on Special Characteristics): Feasibility &
actions to be resolved by FDJ
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Priority
Suppliers
Selected This Evaluation shall occur prior to the supplier’s
shipment of parts of VP builds
Cross- Resolve Open Issues
Functional
Teams Formed
Team Decision
Evaluation Evaluation to Evaluation Evaluation
Kick-Off Proceed
Meetings #1 #2 #3 #4
to Run-
Begin At-Rate
Scope:
• Facilities & Tooling Planning/Installation
• PFMEA & Control Plans
• Gauging
• Staffing & Training Planning
• VP Prototype Build Readiness
• Run-at-Rate Preparation
Timing: PT/UN/UP: Between <FDJ> and Prior to <VP> In Plant Date (IPD)
Participants:
• JLR Joint Lead: PD Engineer , STA Site Engineer
execution of plan to install tools, equipment etc. is on schedule to meet Phased PPAP
requirements.
• If issues are found that have no known solution then these should be escalated in STA & PD and
an AIMS raised - these are the parts that will be tracked by the programme to PPAP sign-off (the
“exceptions”).
APQP emphasis for supplier: Objectives for Evaluation #2
Assessment Deliverable 29
APQP Element 15 Lead Support
PFMEA is complete and has linkages to DFMEA &
PFMEA STA/PD All
Control Plans
Evaluation #2– Expected Outputs
Output Responsibility
2 PD/STA
Acceptance of parts to support VP Prototype Build (prior to
shipment)
3 STA
Concurrence on manufacturing plans in support of Run-at-Rate
event
5 STA
Updated Manufacturing Site Assessment (MSA) – As required
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Supplier
Confirming that NO further changes are required to:
}
Sourcing
Begins • Design All the Inputs to
Phase 0 Shown on
Priority • Tooling & Equipment
Suppliers the Phased PPAP
Selected • Process & Process Parameters Flowchart
Cross- Resolve Open Issues
Functional
Teams Formed
Team Decision
Evaluation Evaluation to Evaluation Evaluation
Kick-Off Proceed
Meetings #1 #2 #3 #4
to Run-
Begin At-Rate
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Team Decision
Evaluation Evaluation to Evaluation
Kick-Off Proceed Evaluation
Meetings #1 #2 #4
to Run- #3
Begin At-Rate
Purpose:
• Completion of PPAP Phase 1
> Dimensional Results
> Production Validation Testing
> Process Capability
> Appearance Approval
Timing:
UN/UP: Between <PEC> and Prior to TT Build In Plant Date (IPD)
Participants:
• If Phase 0: Run-at-Rate has been completed but Phase 1 is not yet achieved, STA must be able to state that the Run-
at-Rate event was successful i.e. all inputs to the event were acceptable, the Control Plan was adhered to, the cycle
time and process yield were as planned. Why? To ensure that the only obstacles to Phase 1 Approval are the
• If the signed Capacity Analysis Report shows a risk to volume it and the CCAR raised to fix the problem should be
escalated in STA. This allows known & predicted volumes to be used at LR milestone decision making (LR decisions
Objective: Support Programme Launch Decisions for parts that are not
PPAP Phase 1 for TT (Exceptions)
Deadline: LR, continues until PPAP Phase 2 completed
• Why? For parts that are not PPAP Phase 1 by TT, Supplier must provide quality
data to allow JLR Programme team to make a informed decision.
• This means warranting all completed PPAP Elements, and providing a risk / confidence
• Data should be available to support this statement and would normally include details of a
modified Control Plan. (Basis of IPSW as mandated for saleable units - see Phased PPAP
Output Responsibility
2 STA/PD
Signed Phase 1 PPAP warrant
(and Phase 2 PPAP if single production workstream)
3 STA
Updated Manufacturing Site Assessment (MSA) – As
required
4 All
Agreement of timing for next evaluations
Evaluation #4
Unit Unit
PTC PA
PTC/ M1 LR/
PTCC M1DJ PA FDJ VP PEC FEC TT PP MP1
Team Decision
Evaluation Evaluation to Evaluation Evaluation
Kick-Off Proceed
Meetings #1 #2 #3 #4
to Run-
Begin At-Rate
Purpose:
• Completion of PPAP Phase 3
> Operators Staffed and Trained
> Ability to Meet Launch Ramp-Up Curve
> Ability to Meet Ongoing Production
> OEE Confirmation
> ToPT/UN/UP:
Timing: determine capacity
Betweenrisks,
PECongoing work
and MP1 & monitoring
Build In Plant Date (IPD)
Participants:
• Lead: STA Site Engineer
3 Craftsmanship PD
7. Colour Changes Completed Supporting Color Harmony
• This means warranting all completed PPAP Elements, and providing a risk / confidence
statement for the PPAP Elements that are not complete, including making a statement of
• Data should be available to support this statement and would normally include details of a
modified Control Plan. (Basis of IPSW as mandated for saleable units - see Phased PPAP
Output Responsibility
2 STA
Signed Phase 3 PPAP Warrant and Capacity Analysis Report
3 STA
Updated Manufacturing Site Assessment (MSA) – As required
How much of the activity has been completed (C) as a percentage of the total required?
What is the list of Work In Progress Red’s we have – CCAR’s : not Programme Critical yet
From the deliverables is there a specific area we need to deep dive, e.g. DFMEA?
What are the key escalation issues we need to take to the program team for escalation?
Enforce the use of the Action Plan Summary Section for Key Escalation Issues
Those that will affect programme viability if not fixed now or in the near future, i.e.
within the next reporting cycle.
90
80
70
60
1st Qtr
Metrics – to show
2nd Qtr
%age Complete as
50 East
40 West 3rd Qtr
30 North
20
10
0
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr
Program escalated
Red List
APQP
Key Issues List support plan and
Assessment
actions
Deliverable list
for escalation
Assessments
review
CCAR
Enforce the use of the Action Plan Summary Section for Key Escalation Issues and
Actions that will affect programme viability if not fixed now or in the near future
The key escalation issues and actions are those that must be escalated to be fixed because
they are critical to the programme now, or will be by the next reporting cycle (next month).
If there are NO key escalation issues and actions state this in order to avoid doubt– make sure
we put in the +ve statement
Summary
• APQP integrates JLR’s activities & the Supplier’s activities, and is a Team-based
process
• Priority Suppliers require enhanced engagement. The terms Priority Supplier & High
Feasibility
• The APQP Assessment is a key form of communication between JLR and the supplier
in the PMST
• JLR uses the information to assess risks, solve problems, make decisions – up to and
including Board level
• PPAP is based upon the Supplier warranting that they can meet JLR’s requirements
Additional Information