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Apqp - Forms
Apqp - Forms
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Appendix Reference
Appendix_8
Revision
4/27/2007
Appendix_9
4/27/2007
Appendix_21
6/9/2006
Appendix_11
11/3/2008
Appendix_6_1
11/21/2008
Appendix_6_1
3/12/2008
Appendix_15
2/20/2008
6
7
9/6/2005
9/6/2005
10
9/6/2005
Issue
No.
Issue
Origin/Date
Part Number(s):
Program(s):
Part Name:
Issues
Description and/or Sketch
Responsibility
Assigned
Date/Status
Date
Action Plan
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Progress Key:
Issue Identified
Issue Resolved
Forecast
Completion
Date
Progress
Part Number(s):
(CL)
(CL)
(CL)
PPAP Date:
Supplier Contact:
Supplier Telephone:
Description:
Tool Supplier
AQE/SQE Contact:
AQE/SQE Telephone:
(If applicable):
MY/Program:
Program Event
SOP Date:
Start
Planned
(mm/dd/yy)
Finish
Actual
(mm/dd/yy)
Planned
Status
Comments
Actual
Manufacturing Address
Supplier Name
Contacts
Sales Contact
Product Engineer
Quality Resident
Program Manager
in Sales Office
Program Manager
in Manufacturing Facility
APQP Contact
Quality Manager
Quality Engineer
PRR Response
Responsibility
Delphi Engineering
Delphi Buyer
Delphi SQE
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
A. General
1
a
- Special tooling?
Revision Date:
Pg. 1 of 3
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
B. Engineering Drawings
14 Are reference dimensions identified to minimize
inspection layout time?
15 Are sufficient control points and datum surfaces
identified to design functional gages?
16 Are tolerances compatible with accepted
manufacturing standards?
17 Can existing and available inspection technology
measure all design requirements?
18 Is the customer designated engineering change
management process used to manage engineering
changes?
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
D. Material Specification
26 Are special material characteristics identified?
27 Where the organization is design responsible, are
specified materials, heat treat and surface
treatments compatible with the durability
requirements in the identified environment?
28 Where required, are the material suppliers on the
customer approved list?
29 Has the organization developed and implemented
a process to control incoming material quality?
30 Have material characteristics requiring inspection
been identified?
If so,
a - Will characteristics be checked in-house?
b - If checked in-house, is test equipment available?
c - If checked in-house, are competent people
available to assure accurate testing?
31 Will outside laboratories be used?
a - Does the organization have a process in place to
assure laboratory competency such as accreditation?
NOTE: Competency needs to be assured,
regardless of the organization's relationship with
the laboratory.
32 Have the following material requirements been
considered:
a - Handling, including environmental aspects?
b - Storage, including environmental aspects?
c - Have the materials/substance composition been
reported in accordance with customer requirements
e.g., IMDS?
d
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
1
a
b
c
d
2
Revision Level
- New materials?
- Quick change?
- Volume fluctuations?
- Mistake proofing?
Have lists been prepared identifying: (Include all
suppliers)
a - New equipment?
b - New tooling?
c - New test equipment (including checking aids)?
3
4
5
6
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
3
4
5
a
b
c
d
6
a
b
c
7
a
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
b - Capability studies?
c - Problem solving?
d - Mistake proofing?
e - Reaction plans?
f - Other topics as identified?
8
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
c - Reference samples?
d - Inspection logs?
19 Have provisions been made to certify and calibrate
gages and test equipment at a defined frequency
that is appropriate?
20 Have required measurement system capability
studies been:
a - Completed?
b - Accepted?
21 Have initial process capability studies been
conducted per customer requirements?
22 Are layout inspection equipment and facilities
adequate to provide initial and ongoing layout of
all details and components in accordance with
customer requirements?
23 Is there a documented procedure for controlling
incoming material that may include, for example,
the following items:
a - Characteristics to be inspected?
b - Frequency of inspection?
c - Sample size?
d - Designated location for approved product?
e - Disposition of nonconforming products?
24 Have sample production parts been provided per
customer requirements?
Revision Date:
Pg. 3 of 4
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
a - Of adequate size?
b - Properly lighted?
6
7
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
Revision Date:
Pg. 1 of 1
Prepared By:
6
7
8
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
4
5
6
8
9
Revision Level
Yes
No
N/A
Comment/Action Required
Person
Responsible
Due
Date
Engineering Input
Latest part prints and specifications
Program Timing / Critical Characteristics
Technical Documents including sub-component drawings.
Program Information such as estimated annual usage, PPAP dates, SOP dates, etc.
Pilot and Prototype requirements and timing.
Key/Critical characteristics for PPAP
Supplier Input
Supplier Scorecard, be prepared to discuss
Updated supplier information (Supplier Profile) including contact list.
Program Timing including tooling, PPAP, R@R
Supplier issues/concerns caused by Delphi Delphi.
Supplier issues/concerns not associated with Delphi.
Questions/concerns needing to be addressed by Delphi
Page 19
DELPHI
Date of Review:
Supplier :
Supplier Duns:
Supplier/Mfg Location:
Critical process sub-tiers for heat treating, coating and plating must comply with the AIAG assessment requirements stated in CQ9, 11 and 12. Including qualified auditors
to complete the assessments. See Section K
PART NUMBER
DESCRIPTION
MODEL
YEAR
DELPHI
START OF
PRODUCTION
PLATFORM
HIGH VOLUME
SCENARIO
(Vehicles)
1
2
3
4
5
6
CHECK IF IN ATTENDANCE
DELPHI CONTACTS
TITLE
AQE
SQE
BUYER
PROGRAM MGR
PPAP COORDINATOR
COMPONENT ENGINEER
PRODUCT ENGINEER
RESPONSE TEAM
NAME
PHONE
NAME
PHONE
SUPPLIER CONTACTS
PRESIDENT
QUALITY MANAGER
KEY CONTACT
PPAP CONTACT
QUALITY CONTACT
RUN@RATE CONTACT
COMPLETE (Ctrl-g)
(Ctrl-y)
Product Application
Does the supplier have working knowledge of the
A following items?
1
2
3
4
Issues
Description and/or Sketch
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Issues
Description and/or Sketch
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Design Review
(Ctrl-r)
Page 20
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Program Information
Platform
Model Year
Delphi Estimated Annual Volume
Supplier PPAP Due Date
Delphi SOP
Delphi Manufacturing Site
Supplier Quoted Tool Capacity (5 days)
Prototype requirements.
Pre-Production Requirements
Other Product Requirements
E components.
1
2
Supplier
G correlated?
Has Delphi received the suppliers plan for dimensional layout and
measurement of the component? (Should include the measurement
1.1 methods, layout, datums, tools, equipment and fixtures (if applicable))
Has engineering reviewed and approved the supplier plan for
1.2 dimensional layout and measurement?
Has the Delphi Receiving Facility, reviewed and approved the supplier
plan for dimensional layout and measurement?
1.3 (Applicable for sites with a Receiving Inspection)
Not applicable: The supplier has received dimensional accreditation
1.4 by the using division.
Goal is 2.0
Measurement Equipment #1
& Methodology
Measurement Equipment #2
& Methodology
Page 21
Measurement Equipment #3
& Methodology
Measurement Equipment #4
& Methodology
Measurement Equipment #5
& Methodology
Measurement Equipment #6
& Methodology
Details
Responsibility
Forecast
Completion
Date
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Special Process
For Suppliers and Sub-Suppliers with CQI-9, 11 or 12 requirements,
Action Plan
Actual
Completion
Date
Progress
PPAP Guidelines
The link below will take you to the Delphi SUPPLIER PPAP
SUBMISSION CHECKLIST. Utilize the Checklist for PPAP
https://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103457.xls
1
2
3
4
5
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
Details
Responsibility
Forecast
Completion
Date
Action Plan
Actual
Completion
Date
Progress
1 required.
4 results.
Run@Rate Requirements
The link below will take you to the Delphi R@R Plan. Utilize the
R@R Plan for discussions. List potential issues below for tracking
N purposes.
https://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xls
Run@Rate Worksheet
https://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xls
1
2
3
4
5
Page 22
WEBSITE INFORMATION
Determine the suppliers access and working knowledge of each
Details
Responsibility
Forecast
Completion
Date
Page 23
Action Plan
Actual
Completion
Date
Progress
The following instructions are intended to help the AQE/SQE in performing the Program Review. Take a moment to review the
Instructions. The intent of the program review is to engage the supplier in conversations about various aspects of the current
program/parts and determine areas of concern that will need further action.
The form is protected/locked so that users can tab through fields. To allow attachments (such as program rosters) and/or
and/or additional information into any open field within the form, the form can be unprotected. The password is "unlock".
This will allow each user to customize the program review to fit their needs while continuing to use a common form and process.
KCC
QCI
QCC
PPAP
Pass-Through Characteristic
Is a characteristic/feature where an anomoly only declares itself under certain conditions such as environmental stimulation and cannot be tested
in Delphi's operations (i.e. soft tie rods, stepper motor with step loss and steering hose with incorrect rubber component.
Page 24
The first part of the Program Review is an informational list used by Delphi and the Supplier for better communication.
Fill in the following information as thoroughly as possible:
Date of Review
Supplier
-include both the facility name and parent name where applicable
Supplier Duns Code
-this is in reference to the manufacturing site producing the product.
Supplier/Mfg Location
Part Numbers
PPAP Date
Description
Platform
Model Year
SOP Date
Supplier Contacts:
-List key supplier contacts
Key Contact
PPAP Contact
Quality Contact
Run@Rate Contact
Delphi Contacts
-List key Delphi contacts
AQE
SQE
Buyer
Program Manager
PPAP Coordinator
Component Engineer
Product Engineer
Response Team
New Risk Level of Product
-Once the review has been completed, evaluate the program risk based on your findings.
Sections A through M are used to track the progress of the supplier through various aspects of building a new product. Each section
focuses on a specific area and is as comprehensive as possible.
The first columns will be used to color code each line item. Green indicates completed, Yellow indicates Open with recovery plan,
Red indicates the suppliers process will not meet Delphi requirements.
The formatting for these three colors has been automated. Go to the cell you want to change, then hit the following key:
for red use "Ctrl-r"
for yellow use "Ctrl-y" for green us "Ctrl-g" this coding will also show up in black/white copies with patterns for each color.
.
The columns represented in each section are used to promote communication between Delphi and the supplier. It also determines responsibility,
forecasts completion dates, action plans, actual completion dates and progress. Each block is expandable to add information as necessary.
The following gives an explanation of each section:
Section A Product Application
Review how the product will be used at Delphi and the customer, etc.
Review prints/specs/ QCI/KPC, and pass-through characteristic/feature, packaging and labeling requirements.
Page 25
Review with supplier so they understand the final product and it's requirements.
# of parts required, type of product (saleable vs non-saleable) to be recorded.
Consider the measurement req't and techniques that will be used for dimensional layout on the component prior to ppap.
Determine based on the print requirements, customer requirements. Detail this section well.
Based on the item listed in section H, detail equipment and methodologies that will be used.
If your supplier is responsible for the design, this section should be discussed.
Page 26
2
3
4
Volume
Information
5
6
7
8
Forecasted
Builds
11
12
Type of Build:
Parts required Date:
Quantity:
PML
Build when PPAP is required:
Supplier PPAP Due Date
PPAP Level Required
10
Part Number:
Family Parent Part No. (if any):
Prod. Mfg. Loc.:
Comments
16
17
18
Section C:
Run @ Rate :
21
22
Comments:
19
20
Letter Location:
(if less than 40%, may exempt Run @ Rate)
Date:
For Semiconductors Run at Rate is exempt. To ensure commitments are met a CAPACITY STUDY is required.
Page 28
the form.
Section C should be filled in by the AQE. If the part commodity is exempt (see Express form for
criteria), it should be listed in the Commodity Exemption letter signed by the Supplier Quality Manager.
l
This is expected to be one letter listing all exempted commodities and stored in one location for
reference by all of Supplier Quality.
Page 29
Effect
Hazardouswithout warning
Hazardous-with
warning
Very High
High
4
3
2
1
M oderate
Low
Very Low
M inor
Very M inor
None
End Customer
Potential failure mode affects
safe vehicle operation and/or
involves noncompliance with
government regulation without
warning.
Potential failure mode affects
safe vehicle operation and/or
involves noncompliance with
government regulation with
warning.
Vehicle/item inoperable (loss
of primary function); failure
mode may cause customer
walk home, field return, or
durability issue.
Vehicle/item operable but at a
reduced level of performance.
Customer very dissatisfied.
Failure mode may cause
vehicle repairs at Dealer.
Includes Noise issues
(squeak/rattle).
Vehicle/item operable but
comfort/convenience item(s))
inoperable/not performing to
customer expectation (e.g..
Noise)
Vehicle/item operable but
comfort/convenience item(s)
operable at a reduced level of
performance.
Fit and finish item does not
conform. Defect noticed by
most customers.
Fit and finish item does not
conform. Defect noticed by
average customers.
Fit and finish item does not
conform. Defect noticed by
discriminating customers.
No effect.
Delphi Plant
Potential failure mode may
cause unsafe condition for
plant personnel without
warning.
Supplier Plant
Potential failure mode may
cause unsafe condition for
plant personnel without
warning.
See Note #1
See Note #1
See Note #1
See Note #1
See Note #2
See Note #1
See Note #2
See Note #1
See Note #1
See Note #2
Ppk
Ranking
< 0.55
10
> 0.55
> 0.78
> 0.86
> 0.94
>1.00
>1.10
>1.20
> 1.30
> 1.67
Note: Identical to Manual except for Ranking of 1. Manual allows for .01 per thousand (10 PPM)
Effect
PFMEA
10
Absolute Uncertainty
Very Remote
Remote
Very Low
Low
Moderate
Moderately High
High
Very High
Almost Certain
Discrepant parts cannot be made because item has been errorproofed by process/product design.
* Note: Identical to Manual except for Rankings of 6 and 4. Words OR gauging performed on setup and first piece check
moved from a detection of 4 to a detection of 6