Supplier Development APQP

Objectives
AQP Process SAQE Responsibilities Construction Of SAQP Workbook Update & Review Procedure

Supplier Development APQP

Supplier Selection 0 Defects ? Design Feasibility

X
Concept SAQE Responsibility 0 Defects ? Product / Process Maturity

Deliver Manufacture 90 Days of production 0 Defects ? PPAP

Supplier Development APQP

Hard Copy in Folder or Electronic copy on CD Backup or temporary storage of key documents on Lotus notes database Keep as Hard Copy in Folder or Store on Computer Backup or temporary storage of key documents on Lotus notes database

PPA P

APQ

Supplier Development APQP

Contents Page
01 Design Records 02 Engineering Change Documents 03 Customer Engineering Approval 04 Design FMEA 05 Process Flow Diagrams 06 Process FMEA 07 Control Plan 08 Measurement System Studies 09 Dimensional Results 10 Material & Performance Test 11 Initial Process Studies 12 Qualified Laboratory Documents 13 Appearance Approval 14 Sample Product 15 Master Sample 16 Checking Aids 17 Customer Specific 18 Part Submission Warrant

PPA P

Supplier Development APQP

1 2 3 4 5 6 7 8 9 10 11 12 13

SSOW (supplier statement of work) / DSKO (directed supplier kick off) LON (letter of Nomination) AQP kick-off meeting & contacts list Drawing & specification review & quality objectives DVP&R (design verification plan & report) Team feasibility commitment Capacity plan Design FMEA (failure mode & effects analysis) Tool & equipment design & feasibility Gauge design & feasibility Tooling kick-off & purchase order cover Pre-production build plan & purchase order cover Process flow chart & manufacturing floor plan Process FMEA Control plan & control plan special characteristics Pre-launch containment plan Subcontractor PPAP status Packaging specifications & shipping plan 1st Off Tool Parts & dim report Drawing Release for PPAP (Design Freeze) IMDS data base acceptance Production trial run Gauge functionality, certification, & R&R (reliability and repeatability) Process capability study & Status Dimensional Report AAR (appearance approval report) Material certification Product Validation Testing SPSO (supplier process sign-off) - Capacity Verification PPAP Interim PPAP submission approval & master samples

APQ

14

15 16 17 18 19 20 21 22 23 24 25

Microsoft Excel Worksheet

26 27 28 29 30 31

Supplier Development APQP

What is the purpose of the SAQP Workbook

To provide a record of the current status for each element of the AQP process, and to ensure that all outstanding issues have been identified and allocated an owner for corrective action with completion date.

It is not the Intention of the workbook to be the method to communicate issues to the SDT

Supplier Development APQP

Supplier Develops process

SAQE Reviews process and checks workbook Manages Issues

Supplier Updates Workbook

EPIC is updated with Status

Keeps SDT informed

SDT Review

Supplier Development APQP 1. S.S.O.W. / D.S.K.O. & Contacts List

2. L.O.N. (Letter of Nomination)
Review SSOW paying particular attention to Program Timing Project Scope Parts Matrix Rolls and responsibilities. A list is created to identify all project responsible contacts, including telephone numbers and location. Include: Program MGR Buyer Quality Logistics Engineering

Target
To ensure that the supplier has the correct information to develop the product to achieve cost and quality objectives over the product life.

What to Keep
Meeting minutes DSKO Sample of SSOW Sample of the Letter of Nomination

Note The SSOW must be signed by both Supplier and JCA at beginning of project, and failure to comply must be a RED issue.

Supplier Development APQP 3. AQP Kick off Meeting

The APQP kick-off meeting allows supplier to interact with the JCI launch team and opens the lines of communication between the various functions. The frequency of regular meetings is established. The supplier is responsible at the APQP kick-off meeting to either: 1) Review with the launch team the names and dates provided on a completed APQP timing summary. 2) Agree key dates, which are later referenced when completing the form with names and dates. The established target start and completion dates must never be changed, but rather compared with the actual start and completion dates to assess the overall execution success of the original plan.

Target
Workbook is updated with planned dates for each element and these remain fixed target for the duration of the project.

Note What to Keep

SAQP report SAQP Workbook Any changes from the agreed timing must be done on the Issue / Action section of the worksheet.

Supplier Development APQP 4. Drawing & specification review & quality objectives
A team review to facilitate a thorough understanding of the product material and performance specifications is necessary. A comprehensive review helps the team identity the functional, durability and appearance requirements of the component and/or assembly. The product characteristics and process parameters required to effect or control the functional, durability, and appearance requirements are to be determined by the supplier.

Target
Supplier understands design completely and potential control characteristics are identified. Potential improvements and cost reduction opportunities are identified Agreement of all special characteristics

! Note - Safety What to Keep

marked up print Issue Report CRT or equivalent All CC identified in DFMEA must be included in Drawing. Engineering Testing requirements are required on drawing

Supplier Development APQP 5. DVP&R

(Design Verification Plan & Report)

Target
All design defined material and functional tests are compliant

The DVP&R is a summary of all development testing required to ensure the product conforms to defined customer needs and requirements. Testing results are incorporated into the document as they become available.

What to Keep
DVP Report FER_DVP

Supplier Development APQP 6. Team Feasibility Commitment

It is the responsibility of supplier to assess the feasibility of the proposed JCI design and/or product. Supplier must confirm the product can be manufactured as proposed and will meet the specified quality, cost, and delivery terms. The team feasibility consensus is documented and includes a list of all open issues.

Target
Supplier agrees requirements can be manufactured to required quality in serial conditions to the planned volume All Important characteristics to be measured and monitored appropriately

What to Keep
Feasibility report FER_Feasibility

Note
Feasibility confirmation is needed after each engineering change

Supplier Development APQP 7. Capacity Plan

Ensure the suppliers plan to achieve capacity is based on the Peak volumes from SSOW and is achievable. For Component suppliers. Load the planned cycle times into the Master Capacity Plan. Ensure all other components on specified process are also included. For Assembly Suppliers Complete OEE with planned cycle time

Target
To ensure that the supplier has the capacity to produce product at the quoted values + 20% peak volume

What to Keep
1.A 1.B Master Capacity Plan OEE data sheet

Supplier Development APQP 8. Design FMEA

(failure mode & effects analysis)
A DFMEA is a living document continually updated as customer needs and expectations require. Preparing the DFMEA provides the team an opportunity to review the previously selected product and process characteristics and make necessary additions, changes, and deletions. The Chrysler, Ford and General Motors Potential Failure Mode and Effects Analysis reference manual should be used for the acceptable method of preparing a DFMEA.

Target
Unless the supplier is design responsible. The salient points from the customer DFMEA affecting customer satisfaction are available.

! What to Keep
Where possible a copy of the DFMEA should be retained, minimum is copy of the FER_DFMEA

Note - Safety
All CC identified in DFMEA must be included in Drawing.

Supplier Development APQP 9. Tool & Equipment

design & feasibility
Review the suppliers plans for tooling and / or equipment to ensure suitability for quality and project life. All SC & CC should have Poke Yoke included in design to eliminate concerns. For complex tooling or Equipment the Tooling specialists should be involved in this review.

Target
Tooling manufactured is designed to produce expected quality parts for product life.

Note What to Keep

Tool tracker or approved alternative SAQE to monitor supplier management of tool manufacture to achieve tooling milestones

Supplier Development APQP 10. Gauge Design & Feasibility

The gauge system review ensures necessary characteristics are checked, and that calibration requirements, gauge maintenance plans, and financing are established. The approval to begin gauge construction is issued at this meeting. All customer and JCI owned gauges must be identified as such.

Target
The gauges and fixtures used to determine quality, should be available for 1st off tool parts. SC & CC should be measurable from the gauges and used in the capability studies.

What to Keep
Gauge plan

Note
All SC & CC must be gauged preferably with variable result. Ongoing SPC should be done off gauge.

Supplier Development APQP 11. Tooling KO & PO Cover

Ensure that All Tooling has been Kick off in time to achieve PPAP, Purchase Order coverage for all production tooling and equipment is available. A Timing plan is generated to review tool & Equipment development. For complex tooling, involvement of the SD tooling team is required.

Target
To ensure the tooling Is kicked off in time to achieve time plans

What to Keep
No specific document is used but a matrix of all tooling and equipment with completion dates would be required. Tool Tracker

Supplier Development APQP 12. Pre Production Build plan

& PO cover

Target
Supplier has a plan to manufacture parts for key build dates and understands delivery requirements. Purchase orders are in place to cover all pre series and testing parts

A plan of the pre-production build requirements, including parts for testing must be communicated. Purchase order for the parts should have been issued. The project buyer should maintain a list of PO cover

What to Keep
No specific document defined,

Supplier Development APQP 13. Process Flow Chart

(Including floor plan)
A pictorial representation showing all of the steps of a process. This must include detail of all points where SC & CC are influenced and all material movement, storage. Welding and surface treatment should be clearly identified A floor plan with flow lines depicting material movement should be included

Target
To establish the manufacturing route plan and the movement and storage that could have impact on quality and delivery. This forms the structure to develop the PFMEA

What to Keep
Process Flow Chart Sample Floor plan FER_MPFC

! Note Safety
Any part of process that has implications on safety should be clearly identified. ie. Welding Parameters Material Hardening or Conditioning

Supplier Development APQP 14. Process FMEA

(including mistake proofing) A PFMEA should be conducted during product quality planning and before beginning production. It is a disciplined review and analysis of a new/revised process and is conducted to anticipate, resolve, or monitor potential process problems for a new/revised product program. A PFMEA is a living document and needs to be reviewed and updated as new failure modes are discovered.

Target
A formal review of all current quality issues on similar products should be documented and aligned with review of new product. This should be reviewed with the known quality outputs from similar products in production and the lessons learned from them must be completed and

What to Keep
PFMEA FER_PFMEA

! Note - Safety
All processes that effect product safety should be given special attention for control and . Welding Hardening Surface Treatment

Supplier Development APQP 15. Control plan

The production control plan is a written description of the systems for controlling parts and processes. Particular attention should be given to the control of special characteristics The production control plan is a living document and should be updated during the development of the project from Prototype Pre launch and production to reflect the addition/deletion of controls based on experience gained by producing parts. (Approval from JCA is required.)

Target
In conjunction with the PFMEA all the key RPN issues have controls applied to ensure the failure does not appear in production. This includes all measurement equipment and frequency of checks likely to detect failure.

! Note What to Keep

Control Plan FER_Control plan Control plan must be in English or a copy maintained in English. Specific attention should be made to the ongoing control of SC & CC

Supplier Development APQP 16. Pre-Launch Containment Plan

The pre-launch containment plan, is required to prevent defect parts being sent to the customer during a period where the process knowledge is developing. It contains all information necessary to ensure customer understanding of the quality delivered product. This should include, but is not limited to: Dimensional validation of delivered parts, including key measurements including SCs & CCs All deliveries are approved by a person who validates all quality checks have been performed before despatch.

Target
0 defects during pre-launch period

! What to Keep
Measurement reports Inspection reports

Note
Special Attention is needed for all Welding and heat treatment processes

Supplier Development APQP 17. Subcontractor PPAP Status

A key supplier launch responsibility is the development and monitoring of sub-supplier quality systems. To ensure the timely PPAP submission of sub-contractor components this task is tracked in program timing. The sub-contractor PPAP may also be reviewed in the run at rate/process sign off. Supplier must track PPAP documentation for each purchased component:

Target
All parts using in supplied assembly are validated to the same level as the supplied part

! What to Keep
Matrix of all sub-component PPAP Status

Note
All SC & CC, Surface treatment, Heat treatment, welding or conditioning must be traceable through sub component approval.

Supplier Development APQP 18. Packaging Specifications & Shipping Plan

The product quality planning team ensures that individual product packaging is designed, tested and proven out. JCI packaging standards or generic packaging requirements are to be used where appropriate. In all cases, the packaging must ensure that the product performance, appearance and characteristics are not adversely affected by handling and/or shipping. Packaging must be compatible with all material handling equipment. Product must be shipped via a JCI approved carrier.

Target
An agreed method of packaging to ensure all products are received in perfect condition

Note What to Keep

Packaging Specifications form

Supplier Development APQP 19. 1st Off Tool parts & Dim report,
Once tooling is completed it is key to ensure the tooling or equipment can produce a correct part, the manufacturer must provide data to confirm the part produced from the tooling is dimensionally correct before delivery.

Target
To ensure tool or process manufactures a part to the drawing at the earliest opportunity.

What to Keep
Dimensional report

Note
The dimensional report can be from CMM against CAD for this element

Supplier Development APQP 20. Drawing Release for PPAP

Design Freeze
The drawing released must be compatible for the part being PPAPd. there has to be agreement with program manager what is the eng. level for PPAP - than that engineering level has to be released via EPIC

Target
The drawing released must be compatible for the part being PPAPd. No changes to the design are acceptable from this point unless with specific demand from Customer with declared timing implications Or Changes are needed to correct functionality.

What to Keep
Copy of drawing to be included in PPAP Feasibility form

Note
Any changes not agreed in the PPAP release cannot be implemented until 90 days after Job 1

Supplier Development APQP 21. IMDS Data Base Acceptance

The supplier shall provide evidence that the Material/Substance Composition reporting that is required by the customer has been completed for the part and that the reported data complies with all customer-specific requirements.

Target
To ensure that the component data is accepted by JCA in the data base. The IMDS registration number is recorded on the PSW The Number should also be Recorded on the Workbook in the comments for that element

What to Keep
Copy of IMDS acceptance report Sample screen shot

Note
The element is only complete when the part is accepted on the data base

Supplier Development APQP 22. Production Trial Run

For production parts, product for PPAP shall be taken from a significant production run. This significant production run shall be from one hour to eight hours of production, and with the specific production quantity to total a minimum of 300 consecutive parts, unless otherwise specified by the authorized customer representative. This significant production run shall be conducted at the production site, at the production rate (see Glossary) using the production tooling, production gauging, production process, production materials, and production operators. Parts from each unique production process, e.g., duplicate assembly line and/or work cell, each position of a multiple cavity die, mould, tool or pattern, shall be measured and representative parts tested

Target
Process runs under serial production conditions to approved control plan

Note What to Keep

Components for ISIR & Capability Inspection reports Data on production can be used for initial understanding of capacity

Supplier Development APQP

R&R (Reliability And Repeatability

23. Gauge Functionality, Certification, Target

Where special gauges, fixtures, or test equipment are required per the control plan, verify gauge repeatability and reproducibility (GR&R) and proper usage. It is important to ensure that the gauge is detecting error in the part not variation error in how the gauge is used to measure the part.

What to Keep
R&R Study results

Note
ALL gauges should be measured using R&R including attribute gauges

Supplier Development APQP 24. Process Capability Study

The purpose of this requirement is to determine if the production process is likely to produce product that will meet the customers requirements. The initial process study is focused on variables not attribute data. Initial capability must achieve a Cpk of 1.67 minimum with no special causes evident in control chart NOTE Unless approved in advance by JCA , attribute data is not acceptable for PPAP submissions

Target
Validation that each of the SC & CC applied to dimensions is capable of achieving its intended tolerance for product life

! What to Keep
Control chart (Analysed for special causes) Histograms for distribution List of all SC and Cpk PIPC (from CRT agreement)

Note
SPC is a long term process and needs to be continued on key characteristics

Supplier Development APQP 25. Dimensional Report

The supplier shall provide evidence that dimensional verifications required by the design record and the Control Plan have been completed and results indicate compliance with specified requirements. The supplier shall have dimensional results on 6 parts for each unique manufacturing process, e.g., cells or production lines and all cavities, moulds, patterns or dies (see 2.2.18). The organization shall record, with the actual results: all dimensions (except reference dimensions), characteristics, and specifications as noted on the design record and Control Plan.

Target
To confirm that the produced part conforms to the drawing. 6 parts are measured and the master samples should be taken from these. Remaining parts to be available for testing.

What to Keep
Dimensional report Material Test report

Note
The dimensional results for all 6 parts must be recorded separately

Supplier Development APQP 26. AAR (Appearance Approval Report)

A separate Appearance Approval Report (AAR) shall be completed for each part or series of parts if the product/part has appearance requirements on the design record.

Target
Customer approval of all defined surface parts for PPAP submission

What to Keep
AAR Sample

Note
Each part and colour should be measured and the values on AAR must be within design tolerances or Master plaque whichever is agreed

Supplier Development APQP 27. Material Certification

In addition to drawings and performance specifications, material specifications should be reviewed for Special Characteristics relating to physical properties, performance, environmental, handling, and storage requirements. These characteristics should also be included in the control plan. The supplier shall also submit a completed Design Verification Plan and Report that summarizes appropriate performance and functional test results.

Target
Validation that the material used performs to the expectation of the design

Note What to Keep

Material Report Ensure all planned material types conform to design record including regional variations before testing is completed.

Supplier Development APQP 28. Product Validation Testing

PVT assures compliance to all JCI and/or Customer requirements and is required for all new or modified parts. The PV test samples must be taken from a 300 piece production simulated run incorporating production tools and processes. PV testing may only begin after all parts from external sub -suppliers have PPAP approval, or have deviations documented.

Target
Component passes all test capability and dimensional requirements Process achieves all throughput and delivery requirements

What to Keep
Records of compliance not retained in PPAP

Supplier Development APQP 29. SPSO (Supplier Process Sign-Off)

The supplier process sign-off (SPSO) verifies the effective implementation of supplier quality systems and evaluates suppliers manufacturing readiness. The SPSO is initiated prior to the supplier part submission to JCI. The advanced quality engineer (or designate) will schedule and lead the SPSO using the supplier process sign-off form.

Target
Validate the process can produce 0 defect production and planned production speed . All checking and control documentation is in place and operators are trained.

! Note What to Keep

SPSO report WW-PLUS-FR-04-43 SPC is done in a controlled way to an agreed plan. There is a reaction plan available for adverse signals

Supplier Development APQP 30. PPAP Interim

With agreement of Customer an Interim PPAP can be signed with DA, but: Each DA has to be signed by Program manager For each DA there has to be plan for elimination of the deviation DA number has to be mentioned on PSW After DA is eliminated, a new PSW to be signed

Target
The target should always be to not need Interim PPAP but if there is no alternative, then a mechanism must be introduced to ensure that the issues are followed up and full PPAP introduced.

! Note What to Keep

DA Corrective action plan Issues like missing released drawings, should not be covered by DA and if S-AQE is asked to sign PPAP with those issues, SAQE should consult this with SDM before PPAP signing off.

Supplier Development APQP 31. PPAP Submission Approval & Master Samples
PPAP is developed to AIAG 4th Edition PPAPs purpose continues to be to provide the evidence that all customer engineering design record and specification requirements are properly understood by the organization and that the manufacturing process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.

Target
The purpose of PPAP is to determine if all customer engineering design record and specification requirements are properly understood by the organization and that the manufacturing process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.

Note What to Keep

JCA Standard is submission level 3 refer to PPAP presentation for retention requirements An organization supplying standard catalogue production or service parts shall comply with PPAP unless formally waived by the authorized customer representative.

Supplier Development APQP

Task 1
From the provided documents create an AQP folder

Task 2 Create a SAQP Workbook from the folder and set status and comments for each element