APQP 3 - 1 Pan Brand Reporter V7c (586) Rev 19

Advanced Product Quality Planning Status Report (Pan Brand, Europe)
Revision 1/23/2006
Supplier/Org: RICO AUTO INDUSTRIES LTD. Brand: Jaguar,(Lead = VCC) Part Name: Bracket Ac Servo AW 21
Location: GURGAON , INDIA Model Year / Vehicle: SI6-MY2006_20 Part Number: SI63071158630****
Supplier Code: EBL8A FPDS Milestone: <J1> Notice Level: 0

Contact Name/Tel: Maninder Singh / +91-124-2824474 Review Date: 08-Nov-06 REV (19)
(ST)
(CP)
<SI>
<SC>
<PH>
<PA>
<PR>
<CC>
<LR>
<LS>
<J1>
<FS>
FPDS MILESTONE
( ) Denotes Key Element for
Milestone Responsibility Timing
Volvo Milestone G-1 G0 G1 G2 G5 G6 G7 G8 G10 Issue(s) for Red/Yellow Elements Corrective Action / Resolution Plan
Powertrain Milestone 9 8 7 6 5 4 3 2 1 -1 (summarize the concern & resulting risk) (e.g. revise timing, allocate resources)
5-Dec-02
19-Jun-03
18-Nov-03
18-Nov-03
13-Apr-04
1-Sep-04
1-Mar-05
11-Oct-05
3-Jan-06
3-Jan-06
16-May-06
1-Sep-06
Target
APQP ELEMENT Ford Supplier Open Close
Date
7. ESTA not followed as per Mr. Lars Eric 7,9. TA is not mandatory requirement for Volvo.
1 Sourcing Decision () () () R Y G G G G 9. TA not signed Conformed by Jonas, Volvo Corporation
Jonas Prashant 15-Oct-04 10-Oct-05
Decision taken for PCRs (#7 and #8) and PCR 5

under Discussion Tooling order received for PCR 7and 8.
Maninder
2 Customer Input Requirements () () R (R) G G G G Customer Inputs in terms of - TGW, Carryover VOLVO confirmed for non-availability of these data, Petrus
Singh
15-Oct-04 10-Nov-05
issues, quality Goals Warranty Targets, quality Volvo's responsibility.
Targets
3 Craftsmanship () () () () () () (G) (G) (G) (G) (G) N.A TO RICO

1. DFMEA not available with Volvo, Confirmed by
4 Design FMEA () () () () (R) (G) (G) G G G 1. DFMEA not sent to RICO
Volvo.
Petrus 15-Oct-04 28-Aug-05
PCR's (2 nos.) underconsideration by Volvo , MS / Anil

5 Design/Manufacturing Review(s) () () () () () (Y) (Y) (G) (G) (G) (G) design need to be freezed.
PCR Finalised and Implemented at Rico. Petrus
sharma
15-Oct-04 20-Jan-05
Discuss with VOLVO Team DVP&R Tracking is

MS / Anil
6 Design Verification Plan & Report () () () (Y) (G) (G) G G G being Done by VOLVO as per plan & status is Discussed with VOLVO Team. Petrus
sharma
15-Oct-04 30-Aug-05
Green. RICO will be informed for DVP&R Review
11. Run@rate of sub supplier has to be 11. Run@rate of sub supplier demonstrated and Mkj / anil
7 Subcontractor APQP Status () () () () (Y) (Y) (G) (G) G G esatablished established Sharma
15-Oct-04 30-Aug-05
9. All proecss are being reviewed for MS / Anil

9. Under Review , Mistake Proofing done as per
8 Facilities, Tools & Gauges () () Y Y (G) (G) G G mistakeproofing.
sc/cc
Petrus sharma / Rajiv 15-Oct-04 30-Aug-05
Gangwar
Sc/ Cc are to be defined by Volvo. Sc/ Cc are defined by Volvo. MS/Anil

9 Prototype Build Control Plan () () (Y) G G G G G CRT not established. CRTsigned
Petrus
Sharma
15-Oct-04 28-Aug-05
Maninder
10 Prototype Build(s) () (Y) (G) G G G G Volvo to support for Proto Build Rico will support for Proto Build
Singh
15-Oct-04 30-Aug-05
Tooling order received for PCR 7 and 8.

Design not freeze. Decision to be taken for PCR #5 MS / Anil
11 Drawings & Specifications () (Y) Y (G) G G G and PCRs (#7 and #8) under Discussion
Latest Drawing Rev. 017 (Bkt 683) and Rev. 8 Petrus
sharma
15-Oct-04 10-Nov-05
(Assy. 586)
Tolerance issues are being discussed in the Issue

Tolerances will be discussed and finalised
deck. MS / Anil
12 Team Feasibility Commitment () (G) G (G) G G G 12. Engineering actions , Quality & reliability
12. Engineering actions , Quality & reliability Petrus
sharma
15-Oct-04 30-Aug-05
Targets discussed with Volvo Team
Targets has not met
MS / Anil
13 Manufacturing Process Flowchart () R (Y) G G G G SC / CC has to decide sc/cc finalised. CRT agreement signed Petrus
sharma
15-Oct-04 28-Aug-05
12. SC/CC to be decided

12.SC,CC decided ,PFMEA completed. MS / Anil
14 Process FMEA () () (G) (Y) G G G G 13. SC / CC has to include in Control Plans
13.sc/cc included in Control Plan sharma
15-Oct-04 30-Aug-05
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Advanced Product Quality Planning Status Report (Pan Brand, Europe)
Revision 1/23/2006
Location: GURGAON , INDIA Model Year / Vehicle: SI6-MY2006_20 Part Number: SI63071158630****

Contact Name/Tel: Maninder Singh / +91-124-2824474 Review Date: 08-Nov-06 REV (19)
(ST)
(CP)
<SI>
<SC>
<PH>
<PA>
<PR>
<CC>
<LR>
<LS>
<J1>
<FS>
FPDS MILESTONE
( ) Denotes Key Element for
Milestone Responsibility Timing
Volvo Milestone G-1 G0 G1 G2 G5 G6 G7 G8 G10 Issue(s) for Red/Yellow Elements Corrective Action / Resolution Plan
Powertrain Milestone 9 8 7 6 5 4 3 2 1 -1 (summarize the concern & resulting risk) (e.g. revise timing, allocate resources)
5-Dec-02
19-Jun-03
18-Nov-03
18-Nov-03
13-Apr-04
1-Sep-04
1-Mar-05
11-Oct-05
3-Jan-06
3-Jan-06
16-May-06
1-Sep-06
Target
APQP ELEMENT Ford Supplier Open Close
Date
7. Functionality & safety Check of equipment &

gauges has to be verified
8. Accuracy & linearity of gauges & test equipment
7 Verified
has to be verified
8. Verified
9. Repeatability & Reproducbility of gauges & test
9. Verified
equipment has to be verified Mkj / anil
15 Measurement Systems Evaluation () () (Y) Y (G) G G G 12. Requalification of Gauges & Test Equipment if
12. Reviewed
Sharma
15-Oct-04 30-Aug-05
13. Reviewed
required.
15. Gauge Instructions & Visual aids prepared to
13. Correlation studies has to perform in case of
assure a fool proof Production
duplicate gauges & tset equipment
15. Gauge Instructions & Visual aids to assure a
fool proof Production
4. Review of KPC / KCC

4. Review of KPC / KCC - Done
5. Critical & Significant Characteristics parameters MS / Anil
16 Pre-Launch Control Plan (Y) (Y) (G) G G G has to be defined .
5. Defined
sharma
15-Oct-04 30-Aug-05
6. SC / CC defined in FMEA
6. SC / CC will be defined in FMEA
MS / Anil
17 Operator Process Instructions () Y (Y) G (G) G (G) () 7. Sc / Cc has to Finalised with Volvo 7. Sc / Cc discussion is under process Petrus
sharma
15-Oct-04 30-Aug-05
Packaging and Material handling has been finalised

between Rico and Volvo. Material Handling Prashant
Packaging Standard finalized. Packaging Std. under
18 Packaging Specifications () () G Y G G (G) G discussion for air fright mode.
between Rico India to UK warehouse is Rico's Akinla Gupta/ Karen 15-Oct-04 28-Feb-06
Responsibility and between UK warehouse to Volvo Kuhlmann
Plants is Volvo's responsibility.
MS / Anil
19 Production Trial Run Y (Y) (G) (G) (G) G 4. OEE analysis has to do . 4. PPAP planned on 23-Mar-06
sharma
15-Oct-04
Sc / Cc Identification will be done as per plan from MS / Anil

20 Production Control Plan G (G) (G) (G) G G Sc / Cc Identification From prelaunch Control Plan
prelaunch Control Plan
Petrus
sharma
15-Oct-04 28-Aug-05
8. Pp/Ppk study to be done for Additional 8. Pp/Ppk study done for Additional Manufacturing Mkj / Anil
21 Preliminary Process Capability Study Y (Y) (G) (G) G (G) Manufacturing Streem. Streem.
Petrus
Sharma
15-Oct-04 10-Oct-06
22 Production Validation Testing G (G) (G) (G) G G 12.Agreement of PV testing in under process Volvo has no data. Confirmed by Volvo Jonas Prashant 15-Oct-04 28-Aug-05
FORD STA / Maninder
23 Part Submission Warrant (PSW) G (G) (G) (G) (G) (G) () Phase 3 PPAP (PSW) to be sign off Phase 3 PPAP (PSW) demonstrated to Ford STA.
Petrus Singh
15-Oct-05 18-Oct-06
Overall APQP Status Rating (GYR) R R G G G G
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Advanced Product Quality Planning - Builds
MILESTONE / BUILD EVENT INFORMATION
PROGRAM INFORMATION
Location: GURGAON , INDIA Model Year/ Vehicle: SI6-MY2006_20 Part Number: SI63071158630****
(dates will show up on linked APQP Status Report and
individual checklists) ###
FPDS MILESTONES (KO) <SI> <SC> <PH> <PA> (ST) <PR> (CP) <CC> HTFB <LR> 1PP FEU <LS> CB (J1) <FS> DPV
1 SI6____2006_20_AW _TORSLANDA 5-Dec-02 5-Dec-02 19-Jun-03 18-Nov-03 18-Nov-03 13-Apr-04 1-Sep-04 1-Mar-05 11-Oct-05 3-Jan-06 3-Jan-06 3-Jan-06 3-Jan-06 3-Jan-06 14-Mar-06 16-May-06 1-Sep-06
2 ________________
3 ________________
4 ________________
5 ________________
6 ________________
7 ________________
8 ________________
9 ________________
10 ________________
BUILD EVENT - PROTOTYPE
Vehicle QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD
1 SI6____2006_20_AW _TORSLANDA
2 ________________
3 ________________
4 ________________
5 ________________
6 ________________
7 ________________
8 ________________
9 ________________
10 ________________
BUILD EVENT - PRODUCTION
QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD QTY MRD
1 SI6____2006_20_AW _TORSLANDA
2 ________________
3 ________________
4 ________________
5 ________________
6 ________________
7 ________________
8 ________________
9 ________________
10 ________________
Copyright© 2001 Ford Motor Company

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Advanced Product Quality Planning - Parts List
RICO AUTO INDUSTRIES LTD.

NOTE: Supplier/ Org: Brand: Jaguar,(Lead = VCC)
- EBL8A
Parts whose timing are not concurrent may not be included on the same APQP. If they
become non concurrent split in to separate APQP Reports
Parts, which are not of the same part family, may not be included on the same APQP Location: GURGAON , INDIA Model Year/ Vehicle: SI6-MY2006_20
All suffixes should be included as complete part numbers.
Vehicle 1 2 3 4 5 6 7 8 9 10
MY2006_20
Part number PSW Date
Notice (change Phase 0 Capacity verification
PMST, Module or 1st OFF tool Run @ Rate Run
Part description Base PMT Comments release
"Chunk" date Phase 1
Prefix Or Complete Suffix number) Interim Phase 3
SI6-
(or Phase 2)
Volvo number Date QTY Date QTY
EXAMPLE
A widget 2S61 AAADF AA Y Y CHA Sub Frame LHD 5dr High series only
Warning Only Use letters and numbers.
If you need to use a seperator please use an underscore ( _ )
Bracket Ac Servo
1 SI6 30711586 30 Y 10-Mar-06 50 23-Mar-06 300 23-Mar-06 18-Oct-06
AW 21
10
11
12
13
14
15
16
17
18
19
20

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Advanced Product Quality Planning - Information
Chief Engineer: PMT leader:
RISK INFORMATION (SITE, TECHNOLOGY, PROCESS, OTHER - HIGH IMPACT ??)

Risk Description Plan to address Risk
TEAM INFORMATION
Team Members Company / Role Tel No. Fax No. Email Remarks
Supplier Exec Champion
Ford Exec Champion
IMDS contact
Supplier Exec Champion
Lars- Erik Lindqvist Purchasing - Buyer
Component Design Engineer (Bracket 298
Bjorn Jonsson
)
Vinod Kurup Ford India - STA kvinod@ford.com
Per Saltin Volvo - SQE psaltin@volvocars.com
Maninder Singh Rico / Manufacturing ( Project Leader ) +91-124-2824434 +91-124-2824200 manindersingh@ricoauto.com
Rico / Marketing ( Volvo Account
Prashant Gupta +91-124-2824328 +91-124-2824200 prashantgupta@ricoauto.com
Manager)
MK Jain Quality Assurance (Rico) +91-124-2824412 +91-124-2824200 mkjain@ricoauto.com
D.k. Manjhi Rico Material Planning & Logistics +91-124-2824423 +91-124-2824200 dkmanjhi@ricoauto.com
Rico / Process Engineering &
Rakesh Nagpal +91-124-2824523 +91-124-2824200 rakeshnagpal@ricoauto.com
Development .
Anil Sharma Rico / Development +91-124-2824412 +91-124-2824200 anilsharma@ricoauto.com
Slankar lal Rico / Quality +91-124-2824412 +91-124-2824200 shankarlal@ricoauto.com
Rajeev Gangwar Rico / Engineering- CAD CAM +91-124-2824463 +91-124-2824200 rajeevgangwar@ricoauto.com
SK Sen Rico/ Die Manufacturing +91-124-2824463 +91-124-2824200 sksen@ricoauto.com
Vivek hazari Rico/ volvo Champion +91-124-2824239 +91-124-2824200 vivekhazari@ricoauto.com
Karen Kuhlman Rico -Europe, Account Manager +91-124-2824200 karenkuhlmann03@aol.com
Berndt Johansson Buyer bjohan38@volvocars.com
Jonas Hallerstrom Buyer jhallers@volvocars.com

Page 5 of 49 - Information Printed: 05/08/2020
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Advanced Product Quality Planning - 1. Sourcing Decision
APQP Element Rating Checklist Sourcing Decision is a formal customer commitment to work with all Internal & External Part
Suppliers, Tooling Suppliers, and Facility Suppliers on the program. Suppliers, and their sub-
1 Sourcing Decision suppliers, should be engaged as early as possible (e.g. by SC) to understand program timing and
requirements. Sourcing Decision should be made with appropriate Quality History & Customer
Current Gate <J1> Input Data.
FPDS Timing Due Dates
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Item Start Target Expectations Issues / Comments / Risks Corrective Actions / Resolution Plan Ford Supplier Open Close
Timing Timing
There are NO major Sourcing Decision issues/inhibitors, that

will create an uncontainable risk now or in the foreseeable
1 KO PA 18-Nov-03 30-Jul-05 G G G G G G
future.
Ensure that the Supplier's Quality History is factored into the

Sourcing Decision for all Phases of the Sourcing Decision
2 KO SI 5-Dec-02 dd-mmm-yy G G G G G G
including Global Logistics concerns.
(e.g. Supplier Improvement Metrics (SIM) database).
Ensure that Ford Global Logistics is aware of all selected
3 KO SI 5-Dec-02 dd-mmm-yy G G G G G G
suppliers at the SI Milestone.
Complete and communicate the Sourcing Decisions to the
4 KO SC 19-Jun-03 dd-mmm-yy Part, Tooling & Facility Suppliers/Sub-Suppliers by the SC G G G G G G
Milestone.
Ensure that all appropriate Part, Tooling and Facilities
Suppliers/Sub-Suppliers are on-board and involved with the
5 KO SC 19-Jun-03 dd-mmm-yy G G G G G G
Program Team early enough to understand all requirements
including Craftsmanship targets.
Ensure that Assembly and Stamping Plants are aware of all

6 KO SC 19-Jun-03 dd-mmm-yy R G G G G G
selected Suppliers. (see APQP Element "Customer Input").
The Early Sourcing Target Agreement (ESTA) and Reliability

Statement of Work, Engineering Statement of Work, etc., TA is not mandatory requirement for Volvo.
7 SI PA 18-Nov-03 30-Jul-05 R G G G G G ESTA not followed Jonas Prashant 15-Oct-04 10-Oct-05
have been signed by Purchasing, Product Development and Conformed by Jonas, Volvo Corporation
the Supplier.
The supplier is aware of, and capable of meeting, a Virtual Build Programme information & quantity
8 KO SC 19-Jun-03 dd-mmm-yy G G G G G G Reveived
Build Programme. required.for all the Plants
For Volvo:
The Target Agreement (TA)
and Reliability Statement of Work, Engineering Statement of TA is not mandatory requirement for Volvo.
9 SI PA 18-Nov-03 30-Jul-05 R Y G G G G TA not signed Jonas 15-Oct-04 10-Oct-05
Work, Job Split running prod. (direct sourced suppliers ,x- Conformed by Jonas, Volvo Corporation
marked ) etc., have been signed by Purchasing, Product
Development and the Supplier.
7,9. TA is not mandatory requirement for
7. ESTA not followed as per Mr. Lars Eric
Overall KO PA 18-Nov-03 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) R Y G G G G 9. TA not signed
Volvo. Jonas Prashant 15-Oct-04 10-Oct-05
Conformed by Jonas, Volvo Corporation
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 2. Customer Input Requirements
APQP Element Rating Checklist Customer Input Requirements are the design criteria and the program requirements necessary to initiate the APQP process. They include Design Goals,
Reliability and Quality Goals, Program Timing, Affordable Cost Targets, Capacity Planning Volumes, Key Contact Personnel, and input requested from &
2 Customer Input Requirements supplied by the Manufacturing Facilities involved. This is done to assure that any current Manufacturing/Process issues are addressed appropriately by the new
Current Gate <J1> design and process, early in the Product Development cycle.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Decision taken for PCRs (#7 and #8) and

There are NO major Customer Input issues/inhibitors, that will PCR 5 under Discussion Tooling order received for PCR 7and 8.
1 SI CP 1-Mar-05 30-Jul-05 create an uncontainable risk now or in the foreseeable future. R R G G G G Customer Inputs in terms of - TGW, VOLVO confirmed for non-availability of Petrus 15-Oct-04 10-Nov-05
Carryover issues, quality Goals Warranty these data, Volvo's responsibility.
Targets, quality Targets
Define the cross-functional team that will be responsible for

benchmarking similar vehicles, reviewing and analyzing the
Quality Data and History, in support of the different target
levels. Members should include representation from
2 SI SC 19-Jun-03 dd-mmm-yy G G G G G G Green ,
Quality/Reliability, Design Engineering, Manufacturing
Engineering, Global Logistics and Manufacturing Planning &
Logistics (MP&L), and the plants, etc.
Develop a list of the key contact personnel within Ford and

Suppliers, including names, locations, and phone numbers of
the Program Managers, Design & Release Engineers,
Purchasing Agent, STA Engineer, and others as appropriate.
3 SI SC 19-Jun-03 dd-mmm-yy G G G G G G Green , VOLVO 15-Oct-04
(NOTE: The Supplier is to request and receive this
information, as applicable, if it is not automatically supplied by
Ford).
Develop an "Action Matrix" from information requested by the

Assembly, Stamping, and other applicable manufacturing
organizations for data describing carry-over issues, current
Volvo & rico are in discussion on the Per Maninder
4 SI SC 19-Jun-03 dd-mmm-yy and potential manufacturing issues, etc., so that the issues G G G G G G Potential Carryover issues not known. 15-Oct-04
issues. Saltin Singh
can be addressed early by design and process
improvements/actions.
Analyze and understand appropriate Vehicle Benchmarking

Data, Quality Data and History of the Vehicle, System,
Subsystem or Component as it applies. Areas to research
include: Craftsmanship information, External Quality
Indicators (Warranty/Customer Satisfaction), Campaigns
(Recalls/Owner Notifications), Fresh Eyes History on outgoing
5 SI PA 18-Nov-03 dd-mmm-yy G G G G G G Green , assumed to be completed by VOLVO VOLVO 15-Oct-04
vehicles, Manufacturing Capability (Cp/CpK), Equipment
Reliability & Maintainability (Machinery FMEA's,
breakdowns/downtime, Preventive Maintenance information),
Health/Safety/Ergonomics, carry-over issues (FCPA/NOVA -C
Audits), First Run, and Repair, etc.
Analyze initial system and component designs and

specifications as they become available, to understand
Product Assumptions, Functional Performance, Dimensions,
Weights, Materials, and Craftsmanship requirements.
6 SI PA 18-Nov-03 30-Apr-05 G Y G G G G Volvo to supply the Information Done VOLVO 15-Oct-04 30-Aug-05
Ford).
Analyze and understand Reliability and Quality Goals

including Functional Performance Specs, 10 yr/150k mileage
Useful Life Reliability (ULRI) Targets, Warranty Targets, and
Reliability & Quality Goals /
Incoming Quality Targets (PPM, etc.). Per
7 SI PA 18-Nov-03 30-Jul-05 R R G G G G Performance ,Quality & Warranty Targets Data not available, confirmed by Volvo. 15-Oct-04 30-Aug-05
(NOTE: The Supplier is to request and receive this Saltin
are not available with RICO
Ford).

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<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Use the Program's Timing Dates to create a plan for APQP

requirements, Program Status Reviews, Design Freeze,
Prototype Builds, Material Required Dates, and Job#1
8 SI PA 18-Nov-03 dd-mmm-yy (NOTE: The Supplier is to request and receive this G G G G G G 15-Oct-04
Ford).
Prepare a Total Cost review for the applicable affordable cost

targets, as they are defined for the Program, including peak
volumes.
Tool Cost under review for applicable
9 SI PA 18-Nov-03 30-Jul-05 (NOTE: The Supplier is to request and receive this G Y G G G G Reviewed 30-Aug-05
affordable cost Targets.
Ford).
Understand the Capacity Planning Volumes as they are

defined for the Program.
10. SI PA 18-Nov-03 dd-mmm-yy G G G G G G confirmation on Volumes by Volvo volvo has to send the CPV
Ford).
Understand any related logistic requirements, (including

locations of suppliers), and volume requirements (including
Logistics Discussion under preliminary To be discussed & finalised in next
11. SI PA 18-Nov-03 dd-mmm-yy packaging concerns, density of containers and frequency of Y G G G G G
Stage meeting at VOLVO
shipment).
Understand the appropriate requirements of the Program's

Work Plan including timing , the APQP Elements, the
guidelines for Prototype parts, etc.
12. SI PA 18-Nov-03 dd-mmm-yy (NOTE: The Supplier is to request and receive this G G G G G G APQP elements & Timing plan understood Done
Ford).
Have you loaded 100% of the materials data for all supplied
components in to the international material data system
(IMDS) in accordance with the contractual requirements
agreed at Target Agreement.
Maninder
13. SC CP 1-Mar-05 30-May-05 (Note: This requirement should be fulfilled for components by Y Y G G G G IMDS to be updated by Supplier IMDS Updated 15-Oct-04 10-Jun-05
Singh
the <CP> phase (Volvo Gate5 (G5)) for all programs and
should be updated to reflect any engineering changes for the
life of the component.)
Are all relevant contacts in place to enable Supplier

14 SI SC 19-Jun-03 dd-mmm-yy involvement in Virtual Series, e.g. Virtual Build Manager, PIM Y G G G G G
co-ordinator etc?
Develop a list of the key contact personnel within Ford and

Suppliers, including names, locations, and phone numbers of
the Program Managers, Design & Release Engineers,
PIMPAT Leader, Purchasing Agent, STA Engineer, and
15 SI SC 19-Jun-03 dd-mmm-yy others as appropriate. G G G G G G
Ford). This should be included on the 'Information Sheet' on
the front of this APQP document
Has a definition of 'Virtual Product Program' been

communicated to the Program Team & Suppliers, informing Necessary inputs are to be provided by
16 SI SC 19-Jun-03 dd-mmm-yy R G G G G G Definition is not known to RICO
the availability of physical properties & the virtual toolsets to VOLVO ---- Mr. Petrus
be used for the validation during the Program?
Are all suppliers aware of the Virtual requirements of the
Virtual Requirements are not known to Necessary inputs are to be provided by
17 SI SC 19-Jun-03 dd-mmm-yy program, for example Virtual Build timing, data freeze dates, R G G G G G
RICO VOLVO ---- Mr. Petrus
support required during the Virtual Build Event?

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<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Have the IT Technical aspects of the suppliers deliverables

been clearly stated to the supplier, eg systems, data transfer
18 SI SC 19-Jun-03 dd-mmm-yy requirements, models required for Virtual Builds etc? Are G G G G G G
there issues with access to suppliers data?
Understand the Virtual PIMPAT requirements, i.e. CAD level

Volvo has to explain Virtual PIMPAT
19 SI SC 19-Jun-03 dd-mmm-yy data etc... R G G G G G Volvo has to Discuss
Requirements
For PTO parts, have you received transmittal documents for

20 SI SC 19-Jun-03 dd-mmm-yy R G G G G G Volvo has to send PTC documents Volvo has to Discuss
PTCs (pass through characteristics) ?
VCC Environmental Requirements is completed and
communicated to internal and external suppliers before the
21 PR PR 1-Sep-04 dd-mmm-yy R G G G G G RSMS Has to be communicated by VOLVO Volvo has to Discuss
Milestone and Sign-off of 'Restricted Substance Management
Standard' (RSMS)
Decision taken for PCRs (#7 and #8) and
PCR 5 under Discussion Tooling order received for PCR 7and 8.
Maninder
Overall SI CP 1-Mar-05 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) R R G G G G Customer Inputs in terms of - TGW, VOLVO confirmed for non-availability of Petrus
Singh
15-Oct-04 10-Nov-05
Carryover issues, quality Goals Warranty these data, Volvo's responsibility.
Targets, quality Targets
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 3. Craftsmanship
APQP Element Rating Checklist

Craftsmanship is an assessment of what the customer sees, touches, uses, hears, and smells. It
3 Craftsmanship impacts design and manufacturing, and improves the overall perception of value.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Craftsmanship issues/inhibitors, that will
1 KO J1 16-May-06 dd-mmm-yy create an uncontainable risk now or in the foreseeable future G G G G G N.A TO RICO
per preliminary assumptions/product letter.
Define the Program Attribute Teams (PAT) cross-functional

team for the development and completion of the
Craftsmanship Deliverables for the Program. Members
include: Vehicle Operations (VO), Vehicle Centre Engineering,
Assembly Plants, Stamping Plants, Product Design (PD),
2 KO SI 5-Dec-02 dd-mmm-yy Plant Vehicle Team (PVT) Engineering, Internal & External G G G G G N.A TO RICO
Suppliers, Quality, Manufacturing, Advanced Manufacturing
Pre-Program Engineering (AMPPE), Purchasing, Marketing,
Corporate Design, Research & Vehicle Technology (RVT),
and Ford Customer Service Division (FCSD), as applicable.
Suppliers to participate in Craftsmanship PAT.
Participate and/or support Global Craftsmanship Gateway

3 --- SI 5-Dec-02 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
Attend and participate in Craftsmanship training. (See
4 SI SC 19-Jun-03 dd-mmm-yy http://www.globalcraftsmanship.ford.com/ - "Training G G G G G N.A TO RICO
Instructions" )
5 --- SC 19-Jun-03 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
Prepare and sign Engineering Statement of Work for
subsystem level 1 (SSL1) components, including
6 SI SC 19-Jun-03 dd-mmm-yy G G G G G N.A TO RICO
Craftsmanship targets. Review the ESOW with Global
Craftsmanship prior to signing.
Verify carry-over parts are dimensionally correct to the
7 SI PH 18-Nov-03 dd-mmm-yy released drawings or files, to ensure compatibility to mating G G G G G N.A TO RICO
component(s).
Prepare and sign Engineering Statement of Work for SSL2
8 SC PH 18-Nov-03 dd-mmm-yy components, including Craftsmanship targets. Review the G G G G G N.A TO RICO
ESOW with Global Craftsmanship prior to signing.
Review the Master Section & Package drawings with Global
9 SI PH 18-Nov-03 dd-mmm-yy G G G G G N.A TO RICO
Craftsmanship.
Vehicle/Program Craftsmanship requirements, developed by

the Craftsmanship PAT, have been reviewed and accepted by
the Supply Base and other organizations (e.g. Vehicle Opers.,
10 KO PA 18-Nov-03 dd-mmm-yy Powertrain, etc). Include Craftsmanship VDS, SDS, G G G G G N.A TO RICO
Implementation Plan and Craftsmanship Inviolables. Review
supplier Component Design Specification with Craftsmanship
to verify achievement of program target.
Support the program teams, and provide input of issues and

proposed resolutions into the Craftsmanship Implementation
11 KO PA 18-Nov-03 dd-mmm-yy G G G G G N.A TO RICO
Plan. This Implementation Plan will include supplier led
benchmarking of similar vehicles as defined in ESOW.
Participate/support the development of the verification

12 SI PA 18-Nov-03 dd-mmm-yy G G G G G N.A TO RICO
strategy for surface prove-out.
Support the Capability Concurrence Process: Resolve

13 SI PA 18-Nov-03 dd-mmm-yy inconsistencies between Surface Required Illustrations/ G G G G G N.A TO RICO
Fit&Finish/Dimensional Variation Analysis/plant build data.
Review information in ColorTrax for accuracy and

14 --- PA 18-Nov-03 dd-mmm-yy G G G G G N.A TO RICO
completeness.

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Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Prepare and sign Engineering Statement of Work for SSL3
15 PH PA 18-Nov-03 dd-mmm-yy components, including Craftsmanship targets. Review the G G G G G N.A TO RICO
ESOW with Global Craftsmanship prior to signing.
16 --- PA 18-Nov-03 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
Develop and finalize SRI (Surface Required Illustration) and/or
17 SI ST 13-Apr-04 dd-mmm-yy Fit & Finish requirements. SRI/F&F required at Hard Freeze G G G G G N.A TO RICO
per program VPP.
Electronic Math Surface Data (PDN 2) is complete and
18 PA ST 13-Apr-04 dd-mmm-yy G G G G G N.A TO RICO
resides in Metaphase.
19 --- ST 13-Apr-04 dd-mmm-yy G G G G G N.A TO RICO
completeness.
20 --- ST 13-Apr-04 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
Participate/support the implementation of the verification
21 PH PR 1-Sep-04 dd-mmm-yy G G G G G N.A TO RICO
strategy for surface prove-out.
Support the colour Harmony process with pictorials and
22 PA PR 1-Sep-04 dd-mmm-yy G G G G G N.A TO RICO
material/grain/gloss/colour information.
Review Craftsmanship Data Control Verification Models for

23 ST PR 1-Sep-04 dd-mmm-yy G G G G G N.A TO RICO
performance to objective. Resolve issues from DCM Review.

24 --- PR 1-Sep-04 dd-mmm-yy G G G G G N.A TO RICO
completeness.
25 --- PR 1-Sep-04 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
26 --- CP 1-Mar-05 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
Develop Craftsmanship Implementation Plan resolutions to
27 --- CP 1-Mar-05 dd-mmm-yy achieve craftsmanship targets and close gap to target on pre- G G G G G N.A TO RICO
production builds.
28 --- CP 1-Mar-05 dd-mmm-yy G G G G G N.A TO RICO
completeness.
Update Craftsmanship Implementation Plan resolutions from
29 --- CC 11-Oct-05 dd-mmm-yy pre-production built to achieve production craftsmanship G G G G G N.A TO RICO
targets.
30 --- CC 11-Oct-05 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
31 --- CC 11-Oct-05 dd-mmm-yy G G G G G N.A TO RICO
completeness.
Verify Craftsmanship Objectives are being met on the
32 CP LR 3-Jan-06 dd-mmm-yy G G G G G N.A TO RICO
Prototype Builds. (GCARS Verification)
Update Craftsmanship Implementation Plan resolutions from
33 --- LR 3-Jan-06 dd-mmm-yy pre-production built to achieve production craftsmanship G G G G G N.A TO RICO
targets.
Enter final Confirmation Prototype assessments of the
34 CP LR 3-Jan-06 dd-mmm-yy G G G G G N.A TO RICO
Lessons Learned.
35 --- LR 3-Jan-06 dd-mmm-yy G G G G G N.A TO RICO
completeness.
36 --- LR 3-Jan-06 dd-mmm-yy G G G G G N.A TO RICO
sign-off process.
37 --- LS 3-Jan-06 dd-mmm-yy G G G G G N.A TO RICO
completeness.
38 --- J1 16-May-06 dd-mmm-yy G G G G G N.A TO RICO
completeness.
Rate 1PP and Job1 Product/Vehicles for Craftsmanship
39 --- J1 16-May-06 dd-mmm-yy G G G G G N.A TO RICO
confirmation. (GCARS Verification)
Where Global Craftsmanship process is not being followed,
40 SI J1 16-May-06 dd-mmm-yy are all local craftsmanship deliverables complete for each G G G G G N.A TO RICO
milestone?
Overall SI J1 16-May-06 Team's Overall Rating of this Element ( G/Y/R ) G G G G G N.A TO RICO

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Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
11-Oct-05
13-Apr-04
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 4. Design Failure Modes and Effects Analysis
APQP Element Rating Checklist A Design or Concept FMEA is a systematic approach; used by a design responsible team, to
assure that potential design failure modes and their associated causes have been considered and
4 Design Failure Modes and Effects Analysis (DFMEA) addressed. DFMEA's are to be done concurrently with the design process to allow for the
Current Gate <J1> determined Recommended Actions to positively affect the design.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major DFMEA issues/inhibitors, that will create DFMEA not available with Volvo,
1 SI CC 11-Oct-05 dd-mmm-yy Y G G G G G Volvo to share DFMEA with Rico ###
an uncontainable risk now or in the foreseeable future. Confirmed by Volvo.
If a System FMEA was created, use it as input for the Design

2 SI SC 19-Jun-03 dd-mmm-yy G G G G G G
FMEA(s).
Define the design-responsible cross-functional team for the
development of the DFMEA including manufacturing,
3 SI PH 18-Nov-03 dd-mmm-yy engineering, craftsmanship, assembly, suppliers, etc., as G G G G G G
applicable, and list team names on the DFMEA along with
appropriate header information.
Prepare the Design FMEA using the latest Ford FMEA

4 SI PH 18-Nov-03 dd-mmm-yy G G G G G G
Reference Guide, or AIAG Failure Modes and Effects Manual.
Select the DFMEA's that are to be completed using a method

that focuses on what "changed" in the design, and its effects
on the entire system, not the entire design. (Note: Items to be
assuming that VOLVO has completed this
5 SI PH 18-Nov-03 dd-mmm-yy considered include: Craftsmanship, new designs, new G G G G G G VOLVO has to confirm Volvo 15-Oct-04
activity
technology, new process, modifications to existing design and
system, or processes, and use of an existing design or
process in a new environment or location).
Ensure that DFMEA's are initially complete by Program

6 SI PA 18-Nov-03 dd-mmm-yy R G G G G G DFMEA available & review by rico Done
Approval.
Iteratively update the DFMEA's with test results and additional
7 SI PA-CC 11-Oct-05 dd-mmm-yy information such as Craftsmanship, considering the Y G G G G G under Process Done
Expectations shown below.
Address lessons learned. Review campaigns and recalls (to
prevent future recall failures), user & internal plant concerns,
8 SI PA-CC 11-Oct-05 dd-mmm-yy similar design FMEA's, things-gone-wrong, warranty data, Y G G G G G TGW has to be provided by Volvo VOLVO has to Provide Volvo 15-Oct-04
Failure Mode Analysis, Fault Tree Analysis, and test method
prove outs, etc.
List and describe Failure Modes in physical, technical and/or
9 SI PA-CC 11-Oct-05 dd-mmm-yy Y G G G G G under Process Done
measurable terms.
Address the impact of failures as applicable to each of the
10 SI PA-CC 11-Oct-05 dd-mmm-yy following items: each part, next higher assembly, system, Y G G G G G under Process Done
vehicle, customer wants and government regulations.
Develop a plan to identify gauging techniques and limitations

for potential Significant Characteristics (YS) and Critical
11 SI PA-CC 11-Oct-05 dd-mmm-yy Characteristics (YC). Any limitations in gauging or control Y G G G G G under Process Done
should prompt design changes to eliminate SCs and CCs that
cannot be measured or controlled in production or testing.

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Advanced Product Quality Planning - 4. Design Failure Modes and Effects Analysis
APQP Element Rating Checklist A Design or Concept FMEA is a systematic approach; used by a design responsible team, to
assure that potential design failure modes and their associated causes have been considered and
4 Design Failure Modes and Effects Analysis (DFMEA) addressed. DFMEA's are to be done concurrently with the design process to allow for the
Current Gate <J1> determined Recommended Actions to positively affect the design.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Consider process improvement techniques (DoE, Robustness

Methodology, Mistake Proofing (Poke-Yoke), Global
Sc / Cc identiofiaction has to discuss with
12 SI PA-CC 11-Oct-05 dd-mmm-yy 8D/Prevent Recurrence,…etc) to develop preventative and Y G G G G G Design engr. Must have to provide the Data
design engr.
corrective actions for Severity ratings of 5 - 8, with an
Occurrence of 4 or more and high RPN items.
Assign corrective actions, responsibilities, and completion
dates to reduce Government Regulations non-compliance or
13 SI PA-CC 11-Oct-05 dd-mmm-yy safety issues (e.g. Severity = 9 or 10), high-severity, high- Y G G G G G
occurrence, high-criticality, and high-RPN (Risk Priority
Number) failures.
Update the Design FMEA to reflect design and process
changes. This update includes, as appropriate: reassessment
14 SI PA-CC 11-Oct-05 dd-mmm-yy of Severity, Occurrence, Detection and RPN numbers, in Y G G G G G
addition to new failure modes, and corrective actions due to
test failures.
Ensure that Failure Modes & Error States are communicated

from End-Item/Component analysis up through the
15 SI PA-CC 11-Oct-05 dd-mmm-yy Y G G G G G
subsystem, system, and vehicle level analysis to assist with
higher level warranty and reliability assessment.
Ensure that the DFMEA information is communicated to the

16 SI PA-CC 11-Oct-05 dd-mmm-yy Process FMEA teams, including the SC's and CC's, Y G G G G G DFMEA not sent to RICO Volvo has to confirm ASAP
throughout the design and process development.
Use the DFMEA as a living document and update it with
17 SI PA-CC 11-Oct-05 dd-mmm-yy lessons learned. Note: Customer approval is required for all Y G G G G G assuming that under process at VOLVO To be done by VOLVO
inverted delta parts.
1. DFMEA not available with Volvo,
Overall SI CC 11-Oct-05 Team's Overall Rating of this Element ( G/Y/R ) R G G G G G 1. DFMEA not sent to RICO
Confirmed by Volvo.
Petrus 15-Oct-04 ###
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 5. Design Reviews
For Suppliers, Design Reviews are regularly scheduled meetings led by the supplier's design
APQP Element Rating Checklist activity and must include other affected areas. Manufacturing Reviews are regularly scheduled
5 Design / Manufacturing Reviews meetings used to monitor the status of the manufacturing process development. Within Ford,
Design Reviews are held by the Program Teams. Manufacturing Reviews are reviews of the
Current Gate <J1> Manufacturing Design, Tooling, Equipment & Facilities.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Design/Manufacturing review

PCR's (2 nos.) underconsideration by
1 SI J1 16-May-06 23-Sep-05 issues/inhibitors, that will create an uncontainable risk now or Y Y Y G G G Tooling order received for PCR 7 and 8 Petrus 15-Oct-04 10-Nov-05
Volvo , design need to be freezed.
in the foreseeable future.
Define the appropriate cross-functional team for each type of

Review (e.g. Product Design, Manufacturing Design, Tooling,
Equipment & Facilities) including design engineering,
2 SI SI 5-Dec-02 dd-mmm-yy technical specialists, process engineering, Synchronous G G G G G G
Material Flow (SMF) coordinator, the plant, quality,
dimensional control, appropriate levels of management, etc.,
as applicable.
Schedule meetings at appropriate intervals between

milestones and review the appropriate technical aspects
ON Meetings are held on weekly basis B/w
3 SI 16-May-06 dd-mmm-yy which may affect the design or functional performance. This G G G G G G
GOING VOLVO & RICo
would include Management lead Design Reviews &
Manufacturing Design & Process Reviews.
Ensure that the APQP Status for all internally supplied, and
ON External Suppliers Documents are under PFMEA, Control Plan , APQP status
4 SI 16-May-06 dd-mmm-yy externally supplied parts/systems is documented and G Y G G G G
GOING review reviewed as per Plan
discussed.
Evaluate all design, functional requirements, and the technical
ON
5 SI 16-May-06 dd-mmm-yy aspects of all other APQP elements (e.g. All other APQP Y Y G G G G O.K , Under Process ( Ongoing Process)
GOING
elements, as appropriate).
ON
6 SI 16-May-06 dd-mmm-yy Participate in appearance and clay reviews, as appropriate. N.A
GOING
Ensure that the Reviews contain data reviews of documents
ON including FMEA's, DVP&R, Government Regulations, Control Document review to be done jointly by
7 SI 16-May-06 dd-mmm-yy Y Y G G G G Review not done
GOING Plans, etc., with an emphasis on a Quality-Of-Event for each VOLVO / RICO --- Team
phase of the design and manufacturing process.
ON Ensure that Government Regulations (e.g. stop ships, recalls, Document review to be done jointly by
GOING etc.) and Campaign issues are reviewed. VOLVO / RICO --- Team
ON Ensure that Serviceability and Repairability concerns are Document review to be done jointly by
GOING reviewed. VOLVO / RICO --- Team
Ensure that concerns involving Material Handling, Packaging

ON Engineering (PE), Material Planning & Logistics (MP&L), Document review to be done jointly by
GOING Synchronous Material Flow (SMF), and Global Logistics VOLVO / RICO --- Team
concerns are reviewed during the meetings.
ON Document review to be done jointly by

11 SI 16-May-06 dd-mmm-yy Ensure that Cost concerns are reviewed. Y Y G G G G Review not done
GOING VOLVO / RICO --- Team

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Advanced Product Quality Planning - 5. Design Reviews
For Suppliers, Design Reviews are regularly scheduled meetings led by the supplier's design
APQP Element Rating Checklist activity and must include other affected areas. Manufacturing Reviews are regularly scheduled
5 Design / Manufacturing Reviews meetings used to monitor the status of the manufacturing process development. Within Ford,
Design Reviews are held by the Program Teams. Manufacturing Reviews are reviews of the
Current Gate <J1> Manufacturing Design, Tooling, Equipment & Facilities.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
ON Ensure that issues are tracked and assignments are made to

12 SI 16-May-06 dd-mmm-yy G G G G G G Under Process
GOING work on and resolve any open issues between reviews.
All Software requirements in addendum 5a, are on time with a
13 PH LR 3-Jan-06 dd-mmm-yy G N. A for RICO
high quality of event
PCR's (2 nos.) underconsideration by MS / Anil
Overall SI J1 16-May-06 23-Sep-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G Volvo , design need to be freezed.
PCR Finalised and Implemented at Rico. Petrus
sharma
15-Oct-04 20-Jan-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 5a. Software Testing

When imported from a Version 6 datafile.
5a Software This section has to be re evaluated!!
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Software Statement of Work (SWSOW)
1 PA PA 18-Nov-03 dd-mmm-yy Has a SWSOW including compliance matrix been created &
approved?
Perform ISO/IEC TR 15504 (SPICE) SW process assessment
compliant to Supplier SW Quality Assurance Plan (SSQAP).
2 PA PA 18-Nov-03 dd-mmm-yy Has an assessment been carried out? Have
appropriate SW improvement actions been created and
approved?
Perform 4 different SW Joint Reviews. Have Joint Review 1,
3 PA CC 11-Oct-05 dd-mmm-yy 2, 3 and 4 been carried out? Have minuted actions been
carried out in a timely fashion?
Define project products, processes, schedules, resources, and
4 PH CP 1-Mar-05 dd-mmm-yy responsibilities. Has a SW Development Plan (SWDP) been
created/updated?
Has the SW Development Plan (SWDP) been reviewed and
5 PH CP 1-Mar-05 dd-mmm-yy
approved?
Define project overall SW quality program.
Has a SW Quality Plan (SWQP) been created/updated?
Has the SW Quality Plan (SWQP) been reviewed and
approved?
Define and sign off major SW activities according to SWSOW.

8 PH CP 1-Mar-05 dd-mmm-yy Has a Software Engineering Journal (SWEJ) been
created/updated?
Specify SW related requirements. Have all SW Requirement

9 SC CP 1-Mar-05 dd-mmm-yy Specifications and SW Diagnostics Configurations
(SWRS,SWDC/SSDS) been created/updated?
Have all SW Requirement Specifications (SWRS,

10 SC CP 1-Mar-05 dd-mmm-yy
SWDC/SSDS) been reviewed and approved?
Specify SW architecture and detailed design. Have all SW
Design descriptions (SWDD) been created/updated?
Have all SW Design Descriptions (SWDD) been reviewed and
approved?
Define testing objectives, priorities, and schedules. Has a SW
Test Plan (SWTP) been created/updated?
14 PH CP 1-Mar-05 dd-mmm-yy Has a SW Test Plan (SWTP) been reviewed and approved?
Define detailed test cases and procedures for all SW

15 PH CP 1-Mar-05 dd-mmm-yy requirements. Have all SW Test Descriptions (SWTD) been
created/updated?
Have all SW Test Descriptions (SWTD) been reviewed and
approved?
Record the test results. Have all SW Test Reports (SWTR)
been created/updated?
Have all SW Test Reports (SWTR) been reviewed and
approved?
Describe overall SW project status. Has a monthly (or as
19 PH CP 1-Mar-05 dd-mmm-yy agreed) progress report been submitted to concerned
personnel?
Has Software Engineering Journal (SWEJ) been reviewed and
20 CC CC 11-Oct-05 dd-mmm-yy
approved?
Has Part Submission Warrant (Phase 1 PSW) minimun level 3
21 CC CC 11-Oct-05 dd-mmm-yy
been approved?
Overall SC CC 11-Oct-05 Team's Overall Rating of this Element ( G/Y/R )
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 6. Design Verification Plan Report

The Design Verification Plan is a document that lists the engineering evaluations and tests required
6 Design Verification Plan & Report to establish that the design is fit for use in its intended environment.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major DVP&R issues/inhibitors, that will create

1 SI CC 11-Oct-05 30-Jul-05 Y Y G G G G
an uncontainable risk now or in the foreseeable future.
Define the design-responsible cross-functional team for the Discuss with VOLVO Team DVP&R
development of the DVP including engineering, suppliers, Tracking is being Done by VOLVO as per
manufacturing, suppliers, etc., as applicable, and list the team plan & status is Green. RICO will be
members or appropriate contact names on the DVP. informed for DVP&R Review
Prepare the Design Verification Plan & Report using

3 SI PA-CC 11-Oct-05 dd-mmm-yy appropriate internal procedures and/or Ford Reliability Guide Y Y G G G G
requirements.
Ensure that the DVP is sufficient to validate Federal
4 SI PA-CC 11-Oct-05 dd-mmm-yy Y Y G G G G
Regulations for the specific commodity.
Ensure test design is sufficient to verify Ford corporate and

customer requirements and will "Design for Robustness"
5 SI PA-CC 11-Oct-05 dd-mmm-yy against the 5 sources of noise (i.e. part to part variation, Y Y G G G G
adjoining system, customer usage, wear out/aging, and
working environment).
For Part Variation, specifically consider variation within

tolerance (tolerance extremes) on selected product
characteristics and SC/CCs chosen by the team, and
dimensional wear.
For Environment, specifically consider the effects of the

internal environment created by adjoining systems, and the
external environment (e.g. climate, road surface conditions,
etc.).
For Customer Usage, specifically consider the "90th
8 SI PA-CC 11-Oct-05 percentile" customer usage profile and duty cycles, as well as
the useful life of the product (e.g. 10 yrs/150k miles).
For the System and its adjoining Systems, specifically
9 SI PA-CC 11-Oct-05 dd-mmm-yy consider the effects of physical interfaces between Y Y G G G G
components or systems.
Identify long lead tests, iterative tests, and tests which require
10 SI PA-CC 11-Oct-05 dd-mmm-yy a long time to failure, so that they can begin as soon as Y Y G G G G
possible, and are containable within the test cycle.
Include test (e.g. analytical tests, such as digital buck and

CAE, and physical tests) that are designed to detect a failure
using variable data. (NOTE: A failure is a significant event;
partial, degraded, intermittent, or total product failure).
Document specified tests, methods, equipment, statistical

acceptance criteria, sample sizes, design level and timing.

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Advanced Product Quality Planning - 6. Design Verification Plan Report

The Design Verification Plan is a document that lists the engineering evaluations and tests required
6 Design Verification Plan & Report to establish that the design is fit for use in its intended environment.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Include supplier run tests (which will test the component or

13 SI PA-CC 11-Oct-05 dd-mmm-yy system), and the Ford run tests (e.g. R-310 durability, and Y G G G G G
corrosion, etc.).
Document and approve a corrective action plan for any test

14 SI PA-CC 11-Oct-05 dd-mmm-yy results that do not meet specified design and reliability goals Y G G G G G
to support customer requirements.
Develop an action plan that ensures additional samples will be

tested if failure occurs during the testing phase.
Obtain customer approval for test equipment, if required (e.g.

new technology, not commonly used by customer, etc.)
Provide information to update the SDS, Design and Feasibility

Checklists/Guidelines, and Subsystem and Component
Design FMEA's based on specific failure root causes and
corrective actions, as appropriate.
There are NO major Volvo Analyse and Verification

18 SI CC 11-Oct-05 dd-mmm-yy issues/inhibitors, that will create an uncontainable risk now or G G G G G G
in the foreseeable future. Discuss with VOLVO Team DVP&R
Tracking is being Done by VOLVO as per MS / Anil
Overall SI CC 11-Oct-05 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y G G G G G plan & status is Green. RICO will be
Discussed with VOLVO Team. Petrus
sharma
15-Oct-04 30-Aug-05
informed for DVP&R Review
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 7. Sub-Contractor APQP Status
APQP Element Rating Checklist The Subcontractor APQP Status identifies and reports on the condition of an External Supplier or
Subcontractor's APQP process. It is required that Internal suppliers (within Ford) & External
7 Sub-Contractor APQP Status suppliers cascade APQP requirements to their sub-suppliers or sub-contractors, and conduct
Current Gate <J1> APQP reviews as appropriate.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Sub-Contractor issues/inhibitors, that will Detailed timing plan on all the equipments Mkj / anil
1 SC LR 3-Jan-06 30-Aug-05 Y G G G G G Timing Plan has made , reviewed 15-Oct-04 30-Aug-05
create an uncontainable risk now or in the foreseeable future. and facilities needed. Sharma
Identify the appropriate cross-functional team used to perform

and monitor APQP requirements including part suppliers,
2 SC PH 18-Nov-03 dd-mmm-yy G G G G G G
sister plants, sub-suppliers, system integrators, additional
related suppliers, and the customer (e.g. Ford).
Identify "High Impact" sub-suppliers & sister plants based on,

but not limited to, the following risk factors: new technologies,
3 SC PH 18-Nov-03 dd-mmm-yy new sub-supplier, new facilities, poor quality history, etc. G G G G G G
Provide sub-supplier High Impact list to customer for
consensus.
Develop an APQP Work plan for sub-suppliers and sister

4 SC PH 18-Nov-03 dd-mmm-yy plants that supports the supplier's and vehicle's program G G G G G G
timing.
Identify timing, resources, and responsibilities needed to
5 SC PH 18-Nov-03 dd-mmm-yy support Advanced Product Quality Planning (APQP), per G G G G G G
AIAG requirements, in the work plan.
Work plan timing must be represented in a graphical format

(e.g. Gantt Chart), and all sub-supplier timing dates for each
element are to be adjusted appropriately to complete the
requirements to support the vehicle's program timing.
Perform APQP reviews with sub-contractors on a regular Subcontractor APQP reviews done once /
APQP reviews to be documented as per Mkj / anil
7 PA LR 3-Jan-06 30-Aug-05 basis between Milestones, to ensure ongoing communication Y Y G G G G month & Issue Deck is generated with 15-Oct-04 30-Aug-05
plan Sharma
and progress towards completion. suppliers
Use APQP Checklists to assess Quality of Event and
APQP reviews done as per AIAG manual,
8 PA LR 3-Jan-06 dd-mmm-yy determine ratings for each of the APQP Elements identified in G G G G G G
its an ongoing process
the Status Report.
Obtain or prepare an APQP Status Report for sub-suppliers at

each Milestone or other required interval, track sub-supplier
Subcontractor APQP reviews done & Issue Mkj / anil
9 PA LR 3-Jan-06 30-Aug-05 APQP status in supplier's QOS and provide status and Y Y G G G G Done 15-Oct-04 30-Aug-05
Deck is generated with suppliers Sharma
relevant backup documentation, to the customer (e.g. Ford)
upon request.
Monitor all sub-supplier PSW dates and report to the customer PSW dates & Report is monitored on the Mkj / anil
10 PR LR 3-Jan-06 30-Aug-05 Y Y G G G G Done 15-Oct-04 30-Aug-05
if any fail to meet the vehicle program timing requirements. monthly basis via detailed Timimg Plan Sharma
Verify that sub-supplier's run-at-rate will meet vehicle program Run@rate of sub supplier has to be Run@rate of sub supplier demonstrated Mkj / anil
11 CC LR 3-Jan-06 30-Aug-05 Y Y G G G G 15-Oct-04 30-Aug-05
requirements for launch, ramp-up and production. esatablished and established Sharma
11. Run@rate of sub supplier has to be 11. Run@rate of sub supplier Mkj / anil
Overall SC LR 3-Jan-06 30-Aug-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G esatablished demonstrated and established Sharma
15-Oct-04 30-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 8. Facilities, Tools, Gauges
APQP Element Rating Checklist Facilities, tools, and gauges are those additional, new, refurbished, and relocated resources
required to produce the product at the customer specified quantity and quality levels. Expectations
8 Facilities / Tools / Gauges for this element include but are not limited to planning, statistical and acceptance criteria, lean
Current Gate <J1> manufacturing considerations, qualification of equipment, corrective actions, delivery and setup.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Facilities, Tooling, or Gauge
1 SI LR 3-Jan-06 30-Jun-05 issues/inhibitors, that will create an uncontainable risk now or Y G G G G G
Define the appropriate cross-functional team and process to Under Process Done
identify the Facility, Tooling, and Gauge requirements,
2 SI PA 18-Nov-03 dd-mmm-yy necessary to manufacture the customer specified product at Y Y G G G G
designated quantity and quality levels. (Ref. appropriate
AIAG manuals)
Identify Tooling and Equipment that will be required for the Under Process Done
3 SI PA 18-Nov-03 dd-mmm-yy process with particular emphasis on SC/CC's (e.g. torque, Y Y G G G G
welding, etc).
Identify Test Equipment and Checking Fixtures that will be Under Process Done
required for the process with particular emphasis on SC/CC's
4 SI PA 18-Nov-03 dd-mmm-yy (e.g. torque, welding, etc) and develop a timing plan to Y Y G G G G
support the vehicle program.
Ensure Tooling and Equipment design has provided for a Under Process Done
5 SI PA 18-Nov-03 dd-mmm-yy Flexible System, e.g. Cell Manufacturing, etc. Y Y G G G G
Ensure that Tooling and Equipment design has provided for Under Process Done
6 SI PA 18-Nov-03 dd-mmm-yy Synchronous Material Flow (SMF) and quick change over. Y Y G G G G
Ensure that Tooling and Equipment design has provided for Tooling and Equipment have been made to CPV requirement has to know from Volvo
7 SI PA 18-Nov-03 30-Jun-05 volume fluctuations. Y Y G G G G CPV requirements.
Ensure that Tooling and Equipment design incorporates the Tooling and Equipment design are being Done
MS / Anil
8 SI PA 18-Nov-03 30-Jul-05 recommend actions from the Process FMEA. Y Y G G G G studied to incorporate the reccommnede 15-Oct-04 15-Jul-05
actions from the PFMEA. sharma
Ensure that Tooling and Equipment design has provided for All proecss are being reviewed for Mistake Proofing done for sc/cc MS / Anil 30-Aug-05
9 SI PA 18-Nov-03 30-Jul-05 mistake proofing. Y Y G G G G mistakeproofing. 15-Oct-04
sharma
Obtain agreement of acceptance criteria for tooling and Agreement on the tooling and the Done
MS / Anil
10 SI PA 18-Nov-03 30-Jul-05 equipment between the customer and the supplier of the Y Y G G G G equipmentbetween the customer will be 15-Oct-04 15-Jul-05
equipment. taken from the Ford STA. sharma
Obtain agreement of acceptance criteria for test and checking Agreement on the tooling and the Done
MS / Anil
11 SI PA 18-Nov-03 30-Jun-05 equipment between the customer and the supplier of the Y Y G G G G equipmentbetween the customer will be 15-Oct-04 15-Jul-05
equipment. taken from the Ford STA. sharma
Establish gauge and test and checking equipment feasibility Gauge ,Test checking equipment feasibility Done 30-Aug-05
MS / Anil
12 SI PA 18-Nov-03 30-Jul-05 and accuracy. through Gauge R and R studies. Y G G G G G and accuracy notestablished through R&R . 15-Oct-04
sharma
Ensure that an FMEA has been conducted on all equipment FMEA on Tooling and Equipment not done. Tooling FMEA prepared
MS / Anil
13 SI CC 11-Oct-05 30-Jul-05 and tooling that is new to the process. (Ref. appropriate AIAG Y Y G G G G 15-Oct-04 15-Jul-05
manuals) sharma
Ensure capable gauges are available to run preliminary Gauge review will be conducted to ensure Gauge reviewed conducted to ensure that 30-Aug-05
MS / Anil
14 SI CC 11-Oct-05 30-Jul-05 Process Capability Studies at the tooling and equipment Y G G G G G that capable gauges are available to run capable gauges are available to run 15-Oct-04
supplier's facility. process capability trials. process capability trials. sharma

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Advanced Product Quality Planning - 8. Facilities, Tools, Gauges
APQP Element Rating Checklist Facilities, tools, and gauges are those additional, new, refurbished, and relocated resources
required to produce the product at the customer specified quantity and quality levels. Expectations
8 Facilities / Tools / Gauges for this element include but are not limited to planning, statistical and acceptance criteria, lean
Current Gate <J1> manufacturing considerations, qualification of equipment, corrective actions, delivery and setup.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Conduct an initial preliminary Process Capability Study at the Preliminary process capability at the Preliminary process capability done at the 30-Aug-05
tooling and equipment supplier's facility, prior to shipment to suppliers facility is not done .The same will suppliers facility. MS / Anil
15 SI CC 11-Oct-05 30-Jul-05 the customer. (Ref. appropriate AIAG manuals) Y Y G G G G be done at RICO.Timing to be established 15-Oct-04
sharma
Conduct Preliminary Capability Studies at the customer's Preliminary process capability trials will Preliminary process capability done at the MS / Anil 30-Aug-05
16 SI LR 3-Jan-06 30-Jul-05 manufacturing facility. Y Y G G G G beconducted at RICO.Timing plan not suppliers facility. 15-Oct-04
sharma
fixed.
Develop a training plan that ensures training has been Under Process Done
17 SI LR 3-Jan-06 dd-mmm-yy conducted on new/revised tooling and equipment. Y Y G G G G
Ensure a preventative maintenance plan is complete for Under Process Done

18 SI LR 3-Jan-06 dd-mmm-yy tooling and equipment. Y Y G G G G
Ensure setup instructions for new tooling and equipment are Under Process Done
19 SI LR 3-Jan-06 dd-mmm-yy complete and understandable to the user. Y Y G G G G
MS / Anil
9. All proecss are being reviewed for
9. Under Review , Mistake Proofing done sharma /
Overall SI LR 3-Jan-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G mistakeproofing. Petrus 15-Oct-04 30-Aug-05
as per sc/cc Rajiv
Gangwar
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 9. Prototype Build Control Plan

The Prototype Build Control Plan is a description of the dimensional measurements, material, and
9 Prototype Build Control Plan functional tests that will occur during the confirmation prototype build (e.g. (CP)).
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Prototype Build Control Plan

1 SC PR 1-Sep-04 30-May-05 issues/inhibitors, that will create an uncontainable risk now or G G G G G G N.A
Define the design-responsible cross-functional team for the

development of the Prototype Build Control Plan including
design engineering, process engineering, program and pre-
2 SC PH 18-Nov-03 dd-mmm-yy Y G G G G G N.A
production management, the plant, quality, etc., as applicable,
and list team members or appropriate contacts names on the
Prototype Build Control Plan.
Develop the Prototype Build Control Plan using the latest Ford
internal procedures, and/or Section 6 of the AIAG Advanced
3 SC PH 18-Nov-03 dd-mmm-yy Y G G G G G N.A
Product Quality Planning and Control Plan manual, or
Dynamic Control Planning as appropriate.
Review all product characteristics, identifying those required
4 SC ST 13-Apr-04 dd-mmm-yy for the Prototype Build Control Plan, and obtain design G G G G G G N.A
engineering input and concurrence.
Identify all Potential Significant Characteristics (SCs) and

Critical Characteristics (CCs) from the Design FMEA and
Sc/ Cc are to be defined by Volvo.CRT not MS/Anil
5 SC PR 1-Sep-04 30-Jul-05 include them in the Prototype Build Control Plan. Pay Y G G G G G Sc/ Cc are defined by Volvo. CRTsigned Petrus 15-Oct-04 28-Aug-05
established. Sharma
particular attention to previous Recalls and Owner Notification
Programs on previous models or similar designs.
All process parameters(Tolerances
All process parameters(Tolerances
,Clamping pressures,Tooland Wear part
Document process parameter conditions (e.g. Tolerances) in ,Clamping pressures,Tooland Wear part
replacement frequency,Reaction plan
6 SC PR 1-Sep-04 dd-mmm-yy the Control Plan. Include all special tooling, manufacturing, Y G G G G G replacement frequency,Reaction plan
defining the rolesand resposnibilities
and assembly which are different from the production process. defining the rolesand resposnibilities)will be
visualstandard )not identified in
identified in thecontrolplan.
thecontrolplan.
Define inspection plans for all material and engineering
specifications. Include and record values for all form, fit, and
Material and Engineering specs are not Material and Engineering specs are not
7 SC PR 1-Sep-04 dd-mmm-yy function characteristics for each prototype part. Uniquely Y G G G G G
mentionedon thecontrolplan. mentionedon thecontrolplan.
identify each part and the corresponding values. Include all
PIA parts.
Verify gages and test equipment are accurate, repeatable,

8 SC PR 1-Sep-04 dd-mmm-yy and reproducible with adequate discrimination using the AIAG Y G G G G G R&R studies not conducted. R&R studies will be conducted.
Measurement Systems Analysis (MSA) Handbook.
Inspection reports of all the prototypes are
Document methods to collect and evaluate prototype data for available.Process parameters for the same
9 SC PR 1-Sep-04 dd-mmm-yy Y G G G G G
each serialized prototype part. is also captured.Rejection data for each
opeartion is not analysis recorded.
Clearly state, in the reaction plan(s), that all non-
10 SC PR 1-Sep-04 dd-mmm-yy conformances or repairs require customer authorization prior Y G G G G G
to use.
Give the customer the opportunity to review and approve the control plan will be reviewedandappoved
11 SC PR 1-Sep-04 dd-mmm-yy Y G G G G G
Prototype Build Control Plan. by FordSTA during the PSW.
Sc/ Cc are to be defined by Volvo. Sc/ Cc are defined by Volvo. MS/Anil
Overall SC PR 1-Sep-04 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y G G G G G CRT not established. CRTsigned
Petrus
Sharma
15-Oct-04 28-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06

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Advanced Product Quality Planning - 10. Prototype Build
APQP Element Rating Checklist The Prototype Builds element entails the manufacture or assembly of components, sub-systems,
10 Prototype Build systems, or assembled vehicles (e.g. Confirmation Prototype) that will be supplied to the customer
and built prior to the 1PP production trial run.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Prototype Build issues/inhibitors, that will

1 PH CP 1-Mar-05 dd-mmm-yy G G G G G G
create an uncontainable risk now or in the foreseeable future.
Define the appropriate cross-functional team to prepare for,

2 PH PA 18-Nov-03 dd-mmm-yy G G G G G G
and complete the required Prototype Build.
Ensure that suppliers are involved, as appropriate, and have

3 PH PA 18-Nov-03 dd-mmm-yy received all necessary information with regard to the G G G G G G Volvo to support for Proto Build Rico will support for Proto Build
customer's schedule, prototype quantities and timing.
The supplier/sub-supplier has provided the prototype team a

listing of any design or process prove out requirements/tests
4 PH PA 18-Nov-03 dd-mmm-yy G G G G G G
that require checking at the system or sub-system level in
order to prove out their (supplier/sub-supplier) design.
Ensure that the Prototype Build contains correct level parts

5 PH PR 1-Sep-04 dd-mmm-yy which meet all requirements. (e.g. Performance, Fit/Finish, G G G G G G
Quality, Dimensional, Labelling, etc).
Determine the prototype parts required for internal design

verification testing, (e.g. Key Life, durability, packaging,
function/fit, etc.) in addition to the customer's required
6 PH PR 1-Sep-04 dd-mmm-yy G G G G G G
quantities.
Note: Preliminary testing must be complete prior to <CP>
MRD.
Ensure that the Prototype Build Control Plan was developed,

7 PH CP 1-Mar-05 dd-mmm-yy and is used to identify, and track the items that are to be Y G G G G G
measured on the prototype parts / vehicles.
Develop an "Action Matrix" containing all issues found during

8 PH CP 1-Mar-05 dd-mmm-yy the build and subsequent lab, plant and road testing, and Y G G G G G
review it with the team, and appropriate management.
Ensure that assignments are made to correct issues found in

9 PH CP 1-Mar-05 dd-mmm-yy Y G G G G G Volvo to perform Done Volvo 15-Oct-04
the build and subsequent road testing.
Ensure that Government Regulation, Process Capability, and
10 PH CP 1-Mar-05 dd-mmm-yy Craftsmanship issues are included in the "Action Matrix", as Y G G G G G Volvo to perform Done Volvo 15-Oct-04
appropriate.
Ensure that the Variability Reduction Teams (VRT) are given
the chance to review the Action Matrix, SC/CC's, and complex
11 PH CP 1-Mar-05 dd-mmm-yy Y G G G G G Volvo to perform Done Volvo 15-Oct-04
assemblies for their suggestions on how to reduce variability
issues.
Ensure that Craftsmanship, Fresh Eyes and NOVA-C/FCPA

12 PH CP 1-Mar-05 dd-mmm-yy audits/reviews have been scheduled and conducted on all Y G G G G G Volvo to perform Done Volvo 15-Oct-04
prototype vehicles, beginning with the AP Builds.
Maninder
Overall PH CP 1-Mar-05 Team's Overall Rating of this Element ( G/Y/R ) Y G G G G G Volvo to support for Proto Build Rico will support for Proto Build
Singh
15-Oct-04 30-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
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Advanced Product Quality Planning - 11. Drawings Specifications
APQP Element Rating Checklist The Drawings & Specifications element is an evaluation of the development of Targets and
Specifications as they are defined to be input to the design process (e.g. VDS/SDS/CDS), and to
11 Drawings and Specifications: Design Information the Drawings (including all engineering drawings, CAD data, material specifications and
Current Gate <J1> engineering specifications.)
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Drawings and Specification Design not freeze. Decision to be taken for PCR under review.
MS / Anil
1 SI PR 1-Sep-04 30-Jul-05 issues/inhibitors, that will create an uncontainable risk now or G Y G G G G PCR #5 and PCRs (#7 and #8) under VOLVO confirmed for non-availability of Petrus 15-Oct-04
sharma
in the foreseeable future. Discussion these data, Volvo's responsibility.
Define the cross-functional team for the development of the

Drawings, Specifications, and Quality Targets including design
2 SI PR 1-Sep-04 dd-mmm-yy G G G G G G
engineering, process engineering, suppliers, quality, etc., as
applicable.
ENGINEERING DRAWINGS
3 SI PR 1-Sep-04 dd-mmm-yy Identify dimensions that affect fit, function, durability and G G G G G G
customer satisfaction.
Ensure that Welding Specifications (including Weld Groups or

4 SI PR 1-Sep-04 dd-mmm-yy similar weld classifications) are identified and placed on weld N.A
illustrations and/or drawings.
Ensure that Ford specifications are communicated to the

5 SI PR 1-Sep-04 dd-mmm-yy appropriate engineering functions (including VDS/SDS/CDS) Y N.A
as appropriate.
Ensure that all Government Regulations and Safety

6 SI PR 1-Sep-04 dd-mmm-yy requirements are identified (e.g. FMVSS/CMVSS) and G G G G G G
incorporated into the specifications and drawings.
Ensure all potential Significant/Critical Characteristics are

[3] marked characteristics are considered MS / Anil
7 SI PR 1-Sep-04 dd-mmm-yy identified on the Drawings or attached documents (e.g. G G G G G G sc, cc are to be established by Volvo Petrus 15-Oct-04
as >SC< & need to be confirmed by Volvo sharma
DFMEA, SC/CC Lists, etc.).
Identify reference dimensions to minimize inspection layout

time.
Identify sufficient control points and datum surfaces to design

functional gauges and test equipment.
Ensure tolerances and part specifications are compatible with MS / Anil

10 SI PR 1-Sep-04 30-Jul-05 Y G G G G G Tolerance review under Process Tolerance discussed with Volvo team Petrus 15-Oct-04 28-Aug-05
accepted manufacturing standards for gauges and equipment. sharma
Identify any specified requirements that cannot be evaluated

using known inspection techniques.
MATERIAL SPECIFICATIONS
12 SI PR 1-Sep-04 dd-mmm-yy Identify special material characteristics, (e.g. affected by N.A
temperature, humidity, etc.)
Consider material characteristics to minimize handling,

13 SI PR 1-Sep-04 dd-mmm-yy Y G G G G Handling Process ( Bins ) has to provide Done
storage requirements, and affect to/from the environment.
Design not freeze. Decision to be taken for Tooling order received for PCR 7 and 8.
MS / Anil
Overall SI PR 1-Sep-04 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G PCR #5 and PCRs (#7 and #8) under Latest Drawing Rev. 017 (Bkt 683) and Petrus
sharma
15-Oct-04 10-Nov-05
Discussion Rev. 8 (Assy. 586)
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
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Advanced Product Quality Planning - 12. Team Feasibility Commitment
Team Feasibility determines whether the proposed design can be manufactured within the
APQP Element Rating Checklist guidelines and specifications. A cross-functional design/manufacturing review team is charged
12 Team Feasibility Commitment with assessing design feasibility. Once workability is established, the Program Organization
undertakes the responsibility for the design/manufacturing review process and reassessing
Current Gate <J1> feasibility for any design/part change that may occur.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Team Feasibility issues/inhibitors, that
1 SI CC 11-Oct-05 30-Jun-05 will create an uncontainable risk now or in the foreseeable G G G G G G
future.
2 SI SC 19-Jun-03 dd-mmm-yy identifying the Feasibility Review Process, and the Program G G G G G G
Team Members that must Sign-Off on all Feasibility Issues.
Using the Program Team's defined process for a Feasibility

Commitment Review, identify all engineering issues which
3 SI PR 1-Sep-04 dd-mmm-yy require actions for manufacturing feasibility, and document G G G G G G
them in Ford's Worldwide Engineering Release System
(WERS).
Ensure that the product has been adequately defined (e.g.

4 SI PR 1-Sep-04 30-Jun-05 G G G G G G
application requirements, etc.) to enable feasibility evaluation.
Ensure that all Engineering Specifications can be met as

written.
Ensure that product can be manufactured to tolerances

specified on drawings.
Ensure that product can be manufactured to meet the ongoing

7 SI PR 1-Sep-04 dd-mmm-yy requirements of Cp/CpK >= 1.33, or the specified Customer G G G G G G
requirements (PSW).
Ensure that the design allows for the use of efficient material
handling techniques.
Ensure that the design is considered for ergonomic
9 SI PR 1-Sep-04 dd-mmm-yy manufacturing techniques, and that all issues are resolved G G G G G G
before signoff.
Ensure there is adequate facilities/capability to produce
10 SI CC 11-Oct-05 dd-mmm-yy G G G G G G
product, and consider any potential product/volume changes.
11 SI CC 11-Oct-05 dd-mmm-yy Verify that all WERS concerns are accepted and approved. G G No WERS with RICO
Verify that all engineering actions, and quality/reliability targets Engineering actions , Quality & reliability Engineering actions , Quality & reliability MS / Anil
12 SI CC 11-Oct-05 30-Jun-05 G G G G G G Per saltin 15-Oct-04
have been met and signed off. Targets has not met Targets will be discussed with Volvo Team sharma
13 SI CC 11-Oct-05 dd-mmm-yy Ensure that all WERS concerns are closed. G G No WERS is applicable
Tolerance issues are being discussed in Tolerances will be discussed and finalised
the Issue deck. 12. Engineering actions , Quality & MS / Anil
Overall SI CC 11-Oct-05 30-Jun-05 Team's Overall Rating of this Element ( G/Y/R ) G G G G G G 12. Engineering actions , Quality & reliability Targets discussed with Volvo
Petrus
sharma
15-Oct-04 30-Aug-05
reliability Targets has not met Team
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 26 of 49 - 12. Team Feasibility Commitment Printed: 05/08/2020
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Advanced Product Quality Planning - 13. Manufacturing Process Flow Chart
APQP Element Rating Checklist The Manufacturing Process Flow is a graphic representation of the current or proposed sequence
of manufacturing process. The Manufacturing flow chart can be either in the traditional flow chart
13 Manufacturing Process Flow Chart format, or depicted in Cycle Line Layouts, Tooling Line Layouts, Plant Layouts, or other
Current Gate <J1> appropriate types of layouts, providing all necessary information is included or attached.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Manufacturing Process Flow Chart

1 SC CP 1-Mar-05 30-Jul-05 issues/inhibitors, that will create an uncontainable risk now or G G G G G G
Define the manufacturing-responsible cross-functional team

for the development of the Manufacturing Process Flow Chart
which includes manufacturing, engineering, Material Planning
2 SC PA 18-Nov-03 dd-mmm-yy G G G G G G
& Logistics, Synchronous Material Flow coordinator,
assembly, plants, etc., as applicable, and list the appropriate
contact names on the flow documents.
As a team, decide what format the Manufacturing Process

Flow will use (e.g. traditional flow chart, cycle line drawings,
3 SC PA 18-Nov-03 dd-mmm-yy tooling line layout, plant layout, etc.), and the additional G G G G G G
information the diagram will need to include (e.g. process
information, Dynamic Control Planning, etc.)
Develop the new part process flow, using surrogate part Process Flow using surrogate part process
4 SC PA 18-Nov-03 dd-mmm-yy G G G G G G to be send by VOLVO
process flow charts and existing process FMEAs. flow & process FMEA has to develop
Use the current part Design FMEA as an input to develop the Input from DFMEA has to put to develop
5 SC PA 18-Nov-03 dd-mmm-yy R Y G G G G DFMEA has to be send by VOLVO
process flow. the Process Flow
Illustrate the sequence of production operations, including:

part descriptions, inspection, transportation, storage, all the activities has to be decided on the
6 SC CP 1-Mar-05 dd-mmm-yy R Y G G G G DFMEA has received
subcontracted services, and alternate paths (rework, repair & basis of DFMEA
backup).
Describe how the product will move within the process (e.g.
7 SC CP 1-Mar-05 dd-mmm-yy Y Y G G G G Process movement has to be decided To be done by RICO as per Timing Plan
roller conveyer, slide, containers).
8 SC CP 1-Mar-05 dd-mmm-yy Create a key for symbols used in the flow chart. Y Y G G G G Flow chart symbols has to decide To be done by RICO as per Timing Plan
Identify all appropriate operations affecting special MS / Anil

9 SC CP 1-Mar-05 30-Jul-05 Y Y G G G G SC / CC has to decide sc/cc finalised. CRT agreement signed Petrus 15-Oct-04 28-Aug-05
characteristics (Critical and Significant Characteristics). sharma
Review product and process compatibility issues as part of

10 SC CP 1-Mar-05 dd-mmm-yy Y Y G G G G Product & Process Compatibility issues
flow chart development and process improvement.
MS / Anil
Overall SC CP 1-Mar-05 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) R Y G G G G SC / CC has to decide sc/cc finalised. CRT agreement signed Petrus
sharma
15-Oct-04 28-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 27 of 49 - 13. Mfg Process FlowChart Printed: 05/08/2020
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Advanced Product Quality Planning - 14. Process Failure Mode and Effects Analysis
A Process FMEA is a systematic approach used by a mfg. responsible team to assure that
APQP Element Rating Checklist potential process related failure modes and their associated causes have been addressed and
14 Process Failure Mode and Effects Analysis (PFMEA) resolved.
The Mfg. Process Flow diagrams as well as the Potential SC/Cc's from the DFMEA are used to
Current Gate <J1> ensure that the process is analyzed in the appropriate sequence, with all failure modes addressed.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major PFMEA issues/inhibitors, that will create

1 SC CP 1-Mar-05 30-Jul-05 G G G G G G
an uncontainable risk now or in the foreseeable future.

for the development of the PFMEA which includes design,
2 SC PH 18-Nov-03 dd-mmm-yy process engineering, suppliers, the plant, etc., as applicable, G G G G G G
and list team names on the PFMEA along with appropriate
header information.
Use the latest Ford FMEA Reference Guide, AIAG Failure

3 SC PH 18-Nov-03 dd-mmm-yy Modes and Effects Manual, and/or Dynamic Control Planning G G G G G G AIAG maual followed
reference, as appropriate.
Select the PFMEA's that are to be completed using a method

that focuses on what "changed" in the process, and its effects
on the entire system, (Note: Items to be considered include; PFMEA has to be made on tha basis of PFMEA will be made on tha basis of
MS / Anil
4 SC PH 18-Nov-03 30-Jun-05 Craftsmanship new designs (DFMEA), new technology, new G Y G G G G changed Process & its effect on entire changed Process & its effect on entire 15-Oct-04
sharma
process, modifications to existing design and system, or Process Process
processes, and use of an existing design or process in a new
environment or location).
During preparation of the FMEA's, address lessons learned.

Review campaigns and recalls (to prevent future recall
FMEA has to be made on the basis of
failures), user & internal plant concerns, similar process TGW not available. Confirmed by Volvo. MS / Anil
5 SC ST 13-Apr-04 30-Jul-05 G Y G G G G TGW, warranty data,Failure Mode analysis 15-Oct-04 30-Aug-05
FMEA's, things-gone-wrong, warranty data, Failure Mode PFMEA reviewed sharma
etc.
Analysis, Fault Tree Analysis, and test method prove outs,
etc.
Identify and list all operation numbers and descriptions from PFMEA includes all the Process operation PFMEA includes all the Process operation MS / Anil
6 SC ST 13-Apr-04 30-Jun-05 G Y G G G G 15-Oct-04 30-Jun-05
the Manufacturing Process Flow sequentially on the PFMEA. number & descriptions of flow number & descriptions of flow sharma
List and describe Failure Modes in physical, technical and all failure Modes are described in Physical all failure Modes will be described in MS / Anil
measurable terms. & Technical , measurable terms Physical & Technical , measurable terms sharma
Address the impact of failures as applicable to each of the part, Subsequent operations, system part, Subsequent operations, system
following items: each part, subsequent operation, system, vehicle, customer wants , Government vehicle, customer wants , Government MS / Anil
vehicle, customer wants, government regulations and operator Regulations & operator safety included in Regulations & operator safety included in sharma
safety. PFMEA PFMEA
Describe potential causes in terms that can be corrected and

MS / Anil
9 SC ST 13-Apr-04 30-Jun-05 controlled, for example, people, material, methods, machines, G Y G G G G potential Causes has to be identified, potential Causes will be identified, 15-Oct-04 30-Jun-05
sharma
measurement systems and environment.
Assign corrective actions, responsibilities, and completion

dates to reduce Government Regulations non-compliance or
PR/ Corrective actions has to be decided on the MS / Anil
10 SC 1-Mar-05 30-Jul-05 safety issues (e.g. Severity = 9 or 10), high-severity, high- G Y G G G G Done 15-Oct-04 30-Aug-05
CP basis of RPN sharma
occurrence, high-criticality, and high-RPN (Risk Priority
Number) failures.
Copyright© 2001 Ford Motor Company Page 28 of 49 - 14. Process FMEA Printed: 05/08/2020
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Advanced Product Quality Planning - 14. Process Failure Mode and Effects Analysis
A Process FMEA is a systematic approach used by a mfg. responsible team to assure that
APQP Element Rating Checklist potential process related failure modes and their associated causes have been addressed and
14 Process Failure Mode and Effects Analysis (PFMEA) resolved.
The Mfg. Process Flow diagrams as well as the Potential SC/Cc's from the DFMEA are used to
Current Gate <J1> ensure that the process is analyzed in the appropriate sequence, with all failure modes addressed.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Consider process improvement techniques (DoE, Robustness

Methodology, Mistake Proofing (Poke-Yoke), Global
PR/ Process Improvement techniques are used MS / Anil
11 SC 1-Mar-05 30-Jul-05 8D/Prevent Recurrence, etc) to develop preventative and G Y G G G G Done 15-Oct-04 30-Aug-05
CP with high RPN items. sharma
corrective actions for Severity ratings of 5 - 8, with an
Occurrence of 4 or more and high RPN items.
Identify and verify the SC/CC's obtained from the DFMEA

PR/ MS / Anil
12 SC 1-Mar-05 30-Jul-05 along with any additional process G Y G G G G SC / CC has to be decided sc/cc finalised. CRT agreement signed 15-Oct-04 30-Aug-05
CP sharma
characteristics/Craftsmanship is included.
Ensure that all SC/CC's are controlled and placed on the
PR/ sc/cc finalised. CRT agreement signed. MS / Anil
13 SC 1-Mar-05 30-Jul-05 appropriate Control Plans (e.g. Prototype, Pre-Launch and/or G Y G G G G SC / CC has to include in Control Plans 15-Oct-04 30-Aug-05
CP SC/CC included in Control Plan sharma
Production) or 100 Percent inspected.
Provide Process FMEA and updates to appropriate Design
PR/
14 SC 1-Mar-05 dd-mmm-yy Team and Manufacturing activity with any recommendations G G G G G G PFMEA will provide all the information will be completed using the philosophy
CP
for design changes.
Update the Process FMEA to reflect design and process

changes. Include as appropriate: Lessons Learned,
PR/ reassessment of RPN numbers after corrective actions, Process FMEA has included all the items
15 SC 1-Mar-05 dd-mmm-yy G G G G G G will be completed using the philosophy
CP addition of new Failure Modes, and corrective actions due to mentioned
all test failures. Note: Customer approval of PFMEA's are
required for all inverted delta parts.
For Volvo:
"Identify and list all operation numbers and descriptions from All Operations Numbers & Descriptions
16 SC ST 13-Apr-04 dd-mmm-yy the Manufacturing Process Flow sequentially on the PFMEA, G G G G G G from the Manufacturing Process Flow on will be completed using the philosophy
also including all rework operations as foreseen in the in the the PFMEA
final Process Flow."
12. SC/CC to be decided
12.SC,CC decided ,PFMEA completed. MS / Anil
Overall SC CP 1-Mar-05 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) G Y G G G G 13. SC / CC has to include in Control Plans
13.sc/cc included in Control Plan sharma
15-Oct-04 30-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 29 of 49 - 14. Process FMEA Printed: 05/08/2020
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Advanced Product Quality Planning - 15. Measurement System Evaluation

The Measurement System Evaluation assesses the variation of the measurement system and
15 Measurement System Evaluation determines whether the measurement system is acceptable for monitoring the process.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Measurement System Evaluation

1 SC CC 11-Oct-05 30-Jul-05 issues/inhibitors, that will create an uncontainable risk now or G G G G G G
Define the appropriate cross-functional team to identify the

Measurement System Evaluation requirements including
2 SC SC 19-Jun-03 dd-mmm-yy G G G G G G
dimensional control, quality engineering, process engineering,
the manufacturing facility, supplier, etc., as applicable.
Use the AIAG Measurement Systems Analysis (MSA)

3 SC SC 19-Jun-03 dd-mmm-yy Handbook and appropriate internal procedures to perform the G G G G G G
Measurement System Evaluation requirements.
Develop a plan for gauges and test equipment which

addresses up-to-date proposed timing and cost for both
prototype and production measurement include: Dimensional
Variation Analysis (DVA), Dimensional Control Documentation
4 SC ST 13-Apr-04 dd-mmm-yy G G G G G G
of Locators and Measuring Points, Component and Assembly
Checking and Holding Fixtures, Coordinate Measuring
Machines (CMM's), Data Management, and Prototype
Inspection, as appropriate.
Design new, and modify existing Quality Control gauges and

test equipment to comply with APQP Requirements, AIAG
5 SC PR 1-Sep-04 dd-mmm-yy Measurement System Analysis (MSA), tooling specifications, G G G G G G
Purchase Order agreements, program specific objectives,
Ford tooling standards, and any applicable laws.
Check and verify gauges and test equipment for design

6 SC CC 11-Oct-05 dd-mmm-yy Y Y G G G G Design Confirmation of Gauges are verified Will done by RICO as per Plan
confirmation and appropriate design levels.
Check and verify gauges and test equipment for safety and Functionality & safety Check of equipment Functionality & safety Check of equipment Mkj / anil
7 SC CC 11-Oct-05 30-Jul-05 Y Y G G G G 15-Oct-04 30-Aug-05
functionality. & gauges has to be verified & gauges verified Sharma
Check and verify gauges and test equipment for accuracy and Accuracy & linearity of gauges & test Accuracy & linearity of gauges & test Mkj / anil
linearity with adequate discrimination. equipment has to be verified equipment verified Sharma
Check and verify gauges and test equipment for repeatability Repeatability & Reproducbility of gauges & Repeatability & Reproducbility of gauges & Mkj / anil
and reproducibility with adequate discrimination. test equipment has to be verified test equipment verified Sharma
Ensure that gauges and test equipment meet appropriate

Safety and Government Regulations (e.g. welding, Gauges & Test Equipments are up to the
10 SC CC 11-Oct-05 dd-mmm-yy G G G G G G Will done by RICO as per Plan
torque/TPPS studies, flammability, ECM-Electro Magnetic, mark
etc.)
Ensure that Improvement Plans have been developed and are

Improvement Plan in case of not meeting Mkj / anil
11 SC CC 11-Oct-05 30-Jul-05 in place for all gauge and test equipment that do not meet Y Y G G G G Reviewed 15-Oct-04 30-Aug-05
the criteria Sharma
acceptance criteria.
Ensure that gauges and test equipment are re-qualified to
Requalification of Gauges & Test Mkj / anil
12 SC CC 11-Oct-05 30-Jul-05 criteria detailed in steps 4 thru 7 above, following modification Y Y G G G G Done 15-Oct-04 30-Aug-05
Equipment if required. Sharma
or repair.
Copyright© 2001 Ford Motor Company Page 30 of 49 - 15. Measurement Sys Evaluation Printed: 05/08/2020
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Advanced Product Quality Planning - 15. Measurement System Evaluation

The Measurement System Evaluation assesses the variation of the measurement system and
15 Measurement System Evaluation determines whether the measurement system is acceptable for monitoring the process.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Perform correlation studies when duplicate gauges and test Correlation studies has to perform in case Mkj / anil
13 SC CC 11-Oct-05 30-Jul-05 Y Y G G G G Done 15-Oct-04 30-Aug-05
equipment exist. of duplicate gauges & tset equipment Sharma
Ensure that gauges and test equipment are to the latest

Gauges & test Equipments are to be Mkj / anil
14 SC CC 11-Oct-05 30-Jul-05 engineering level prior to the Production Trial Run, and add Y Y G G G G Done 15-Oct-04 30-Aug-05
calibrated as per&latest
7. Functionality safetyengineering
Check of level. Sharma
them to the Pre-Launch Control Plan.
equipment & gauges has to be verified
Develop gauge instructions and visual aids to assure 8. Accuracy & linearity of gauges & test
Gauge Instructions & Visual aids to assure 7 Verified Mkj / anil
15 SC CC 11-Oct-05 30-Jul-05 appropriate use of the gauges and test equipment in Y Y G G G G equipment Prepared 15-Oct-04 30-Aug-05
a fool proofhas to be verified
Production 8. Verified Sharma
production. 9. Repeatability & Reproducbility of gauges
9. Verified
& test equipment has to be verified Mkj / anil
Overall SC CC 11-Oct-05 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G 12. Reviewed 15-Oct-04 30-Aug-05
12. Requalification of Gauges & Test Sharma
13. Reviewed
Equipment if required.
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
15. Gauge Instructions & Visual aids
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
13. Correlation studies has to perform in
prepared to assure a fool proof Production
case of duplicate gauges & tset equipment
15. Gauge Instructions & Visual aids to
assure a fool proof Production
Copyright© 2001 Ford Motor Company Page 31 of 49 - 15. Measurement Sys Evaluation Printed: 05/08/2020
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Advanced Product Quality Planning - 16. Pre-Launch Control Plan
APQP Element Rating Checklist The Pre-Launch Control Plan is a written description of the dimensional measurements and material and
functional tests (in-process checks) that will occur after the Prototype Builds and before the Production Builds.
16 Pre-Launch Control Plan This plan should include any additional necessary product/process controls until the production process is
validated. Its purpose is to contain potential non-conformances after prototype, but prior to full production (e.g.
Current Gate <J1> 1PP and FEU Builds).
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Pre-Launch Control Plan

1 PR CC 11-Oct-05 30-Jul-05 issues/inhibitors, that will create an uncontainable risk now or G G G G G G

for the development of the Pre-Launch Control Plan which
includes: Design Engineering, Process Engineering, Quality,
2 PR PR 1-Sep-04 dd-mmm-yy Material Planning & Logistics, Packaging Engineering, G G G G G G
Synchronous Material Flow, the plant, etc., as applicable, and
list team members or appropriate contact names on the Pre-
Launch Control Plan.
Develop the Pre-Launch Control Plan using the latest Ford

3 PR PR 1-Sep-04 dd-mmm-yy G G G G G G
Review all product and process characteristics, identifying

4 PR CP 1-Mar-05 30-Jun-05 those required for the Pre-Launch Control Plan, and obtain Y Y G G G G Review of KPC / KCC sc/cc defined. Crt agreement signed 30-Aug-05
Design Engineering input and concurrence.
Identify and include controlling process parameters that have

Critical & Significant Characteristics
5 PR CP 1-Mar-05 30-Jul-05 a direct relationship to the product Special Characteristics, Y Y G G G G sc/cc defined. Crt agreement signed 30-Aug-05
parameters has to be defined .
(e.g. Critical and Significant).
Identify all Significant Characteristics (SCs) and Critical

Characteristics (CCs) from the Process & Design FMEA(s),
6 PR CP 1-Mar-05 30-Jul-05 the customer, Recall, Owner Notification, and other sources, Y Y G G G G SC / CC will be defined in FMEA sc/cc defined. In PFMEA 30-Aug-05
such as Craftsmanship, and include them in the Pre-Launch
Control Plan.
Define inspection plans for all material and engineering Inspection Plan for all material &
7 PR CP 1-Mar-05 30-Jul-05 Y Y G G G G Done 30-Aug-05
specifications. Engineering specifications has to be made
Verify gages and test equipment are accurate, repeatable, Gauges & Test Equipement are to be
8 PR CP 1-Mar-05 30-Jul-05 and reproducible with adequate discrimination using the AIAG Y Y G G G G accurate , repetable as per AIAG MSA Done 30-Aug-05
Measurement Systems Analysis (MSA) Handbook. Hand book
Include appropriate inspection sample sizes and frequencies appropriate inspection sample sizes &
9 PR CC 11-Oct-05 30-Jul-05 Y Y G G G G Defined 30-Aug-05
on the Pre-Launch Control Plan. frequencies are included in Pre launch CP.
Document preliminary process capability requirements,

10 PR CC 11-Oct-05 30-Jul-05 Y Y G G G G Ppk study has to do. Initial Ppk study done 30-Aug-05
including measurement procedures, techniques and datum's.
Ensure that Reactions Plans specify the preventative,

Reaction plans has to made for th
corrective and containment actions necessary to avoid
11 PR CC 11-Oct-05 30-Jul-05 Y Y G G G G preventive , corrective & containment Done 30-Aug-05
operating out-of-control or producing non-conforming
actions necessary to avoid non confirming
products.
Give the customer the opportunity to review and approve the Pre launch CP has to send to Customer for MS / Anil
12 PR CC 11-Oct-05 30-Jul-05 Y Y G G G G 15-Oct-04 30-Aug-05
Pre-Launch Control Plan. approval sharma
Copyright© 2001 Ford Motor Company Page 32 of 49 - 16. PreLaunch Control Plan Printed: 05/08/2020
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Advanced Product Quality Planning - 16. Pre-Launch Control Plan
APQP Element Rating Checklist The Pre-Launch Control Plan is a written description of the dimensional measurements and material and
functional tests (in-process checks) that will occur after the Prototype Builds and before the Production Builds.
16 Pre-Launch Control Plan This plan should include any additional necessary product/process controls until the production process is
validated. Its purpose is to contain potential non-conformances after prototype, but prior to full production (e.g.
Current Gate <J1> 1PP and FEU Builds).
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Document Pre-Launch processes that are different from the Document Pre launch & Production Pre
13 PR CC 11-Oct-05 30-Jul-05 Y Y G G G G OK 30-Aug-05
intended production process on the Pre-Launch Control Plan. launch CP are different.
4. Review of KPC / KCC
4. Review of KPC / KCC - Done
5. Critical & Significant Characteristics MS / Anil
Overall PR CC 11-Oct-05 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G parameters has to be defined .
5. Defined
sharma
15-Oct-04 30-Aug-05
6. SC / CC defined in FMEA
6. SC / CC will be defined in FMEA
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 33 of 49 - 16. PreLaunch Control Plan Printed: 05/08/2020
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Advanced Product Quality Planning - 17. Operator Process Instructions

Operator Process Instructions describe the details of controls and actions that operating personnel
17 Operator Process Instructions must perform to produce quality products.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Operator Process Instruction

1 SI J1 16-May-06 30-Jul-05 issues/inhibitors, that will create an uncontainable risk now or G G G G G G

for the development of the Operator Process Instructions
2 SI PH 18-Nov-03 dd-mmm-yy which includes the plant, manufacturing engineering, G G G G G G
operators/team leaders, environmental, safety, ergonomics,
etc., as applicable.
Ensure that initial elements of the process are adequately

described and documented in process definition/instructions
3 PH CP 1-Mar-05 dd-mmm-yy G G G G G G
for use, operator training, and verification of process steps at
the Confirmation Prototype Build Phase.
Develop a training plan for operators, back-up and repair,

Zone Supervisors, and others as required, to ensure proper
Training Plan for Operators, Supervisors &
execution of process, inverted delta (FMVSS/CMVSS) items, MS / Anil
4 PR CP 1-Mar-05 30-Jun-05 Y Y G G G G Others as per requirement to ensure proper Done 15-Oct-04 15-Jul-05
measurement equipment and gauges, SPC, etc. at each build sharma
execution of process.
phase, starting with the Confirmation Prototype Build, as
appropriate.
Use the lessons learned from the Prototype Build to update

5 CP LR 3-Jan-06 dd-mmm-yy the process definitions/instructions, and prepare them for use G G G G
in the 1PP & FEU builds.
Update the process definitions to include specific operator
6 CP LR 3-Jan-06 dd-mmm-yy allocation to the process steps in preparation for the Pre- G G G G
Launch Builds.
Specify significant/critical characteristics in the Process MS / Anil

7 CP LR 3-Jan-06 30-Jul-05 G G G G Sc / Cc has to Finalised with Volvo Sc / Cc discussed. CRT agreement signed Petrus 15-Oct-04 30-Aug-05
Definition, as appropriate. sharma
Refer to the current Control Plans for inspection, testing,

process monitoring, statistical methods, and reaction plans, as
8 CP LR 3-Jan-06 dd-mmm-yy G G G G
appropriate, in the development of the operator process
instructions.
Include acceptance & rejection criteria for product and Acceptance & Rejection criteria has been MS / Anil
9 CP LR 3-Jan-06 30-Jul-05 G G G G Acceptance & Rejection criteria has made Petrus 15-Oct-04 15-Jul-05
process where appropriate. made sharma
Ensure that the required tools and gauges with calibration

10 CP LR 3-Jan-06 dd-mmm-yy requirements, job set-up, and tool change intervals are G G G G
documented.
Ensure the identification and handling of non-conforming
11 CP LR 3-Jan-06 dd-mmm-yy materials is documented. (e.g. plant practice, control plans, G G G G
etc.)
Include the operation names and numbers, part names and
12 CP LR 3-Jan-06 dd-mmm-yy numbers, revision dates, engineering levels, and appropriate G G G G
approvals.
Copyright© 2001 Ford Motor Company Page 34 of 49 - 17. Operator Proc Instructions Printed: 05/08/2020
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Advanced Product Quality Planning - 17. Operator Process Instructions

Operator Process Instructions describe the details of controls and actions that operating personnel
17 Operator Process Instructions must perform to produce quality products.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Verify process instructions during the Production Trial Run to

13 LR LR 3-Jan-06 dd-mmm-yy
ensure that they can perform as intended.
Include any downstream customer requirements affected by

the operator/operation.
Use the lessons learned from the 1PP & FEU builds to update
15 LR J1 16-May-06 dd-mmm-yy the process definitions/instructions, and prepare them for use
in production.
Demonstrate compliance to the training plan at each build
phase for the latest level of instructions, including execution of
16 LR J1 16-May-06 dd-mmm-yy
process, measurement equipment and gauges, SPC, etc
(Manufacturing facility responsible).
Ensure that process definitions/instructions are accessible and
17 LR J1+ 16-May-06 dd-mmm-yy visible in the work station area. (Manufacturing facility
responsible)
Ensure that visual aids (e.g. FMVSS, Emission labels etc.) are
18 LR J1+ 16-May-06 dd-mmm-yy visible and accessible in the work station area. (Manufacturing
facility responsible)
Maintain and update operator versatility charts/information,

and process definition/instructions, on an ongoing basis to
assure that operation requirements can be filled by multiple
19 LR J1+ 16-May-06 dd-mmm-yy
operators. Particular emphasis should be made on Inverted
Delta (FMVSS/CMVSS)/Government Regulatory operations.
(Manufacturing facility responsible)
20 LR LS 16-May-06 dd-mmm-yy For Volvo questions 15 to 19 have a target of Gate 7 (G7).

MS / Anil
Overall SI J1+ 16-May-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G 7. Sc / Cc has to Finalised with Volvo 7. Sc / Cc discussion is under process Petrus
sharma
15-Oct-04 30-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 35 of 49 - 17. Operator Proc Instructions Printed: 05/08/2020
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Advanced Product Quality Planning - 18. Packaging Specifications
APQP Element Rating Checklist The supplier of a product must ensure that individual packaging for shipment (including interior
18 Packaging Specifications partitions) is designed and developed. Customer packaging standards or generic packaging
requirements should be used when appropriate.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Packaging issues/inhibitors, that will

1 SI LS 3-Jan-06 30-Jul-05 G G G G G G
create an uncontainable risk now or in the foreseeable future.
Packaging Engineering is to participate, along with Logistics

(MP&L) and Purchasing, in the selection process of suppliers
to ensure that Packaging considerations are provided and
understood.
Ensure that the Statement-of-Work (SOW) for suppliers
SOW & other special requirements are
3 SI SC 19-Jun-03 dd-mmm-yy clearly defines appropriate ownership of the container, as well G Y G G G G Volvo has to discuss
communicated to Rico
as any other special requirements.
Ensure that Sourcing (ship points), Transit Modes, FPS

Sourcing Transit Modes , FPs Practices
4 SI SC 19-Jun-03 dd-mmm-yy Practices, and Volumes are understood and optimized for G Y G G G G volvo has to confirm the volume
has to be communicated to Rico
Quality and Total Cost, when analyzing Product Assumptions.
Define the appropriate cross-functional team to prepare for,

and complete the Packaging requirements. Include Ford
Production System (FPS) representation, Packaging
Engineers (e.g. NMP Concept Engineering, In-Plant
Engineering for Assy. and Stamping, and others as required),
Design Engineering, Process Engineering, Plant
representation (Material Handling), Part and Packaging
Suppliers, and Logistics (MP&L).
Ensure that Environmental Targets for the Manufacturing,

6 PA LS 3-Jan-06 dd-mmm-yy Assembly and Stamping Plants are understood, and that G G G G
packaging materials are selected within those requirements.
Ensure that part and packaging suppliers are involved, as Prashant

appropriate, and have received all necessary information with Packaging Proposal has to be send to Gupta/
7 PA LS 3-Jan-06 30-Jul-05 G G G G Packaging Discussion is under process Akinla 15-Oct-04
regard to the customer's schedule, packaging requirements, Volvo for final approval Karen
quantities and timing. Kuhlmann
Ensure that past issues on similar packaging are discussed

8 PA LS 3-Jan-06 30-Jul-05 G G G G
and resolved by the team, in development of new packaging.
Involve the receiving plant during development of the in-plant

containers, plant layout, facility requirements, powered/non-
9 PA LS 3-Jan-06 30-Jul-05 powered equipment, linefeed/storage space, environment, G G G G
and transit modes (rail/truck) to ensure that all issues are
addressed, and all FPS requirements are met.
Ensure that the status of Packaging development is reviewed

10 PA LS 3-Jan-06 30-Jul-05 G G G G
at each Design/Program Review.
Copyright© 2001 Ford Motor Company Page 36 of 49 - 18. Packaging Specifications Printed: 05/08/2020
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Advanced Product Quality Planning - 18. Packaging Specifications
APQP Element Rating Checklist The supplier of a product must ensure that individual packaging for shipment (including interior
18 Packaging Specifications partitions) is designed and developed. Customer packaging standards or generic packaging
requirements should be used when appropriate.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Conduct testing of containers (including laboratory testing) to

11 PA LS 3-Jan-06 30-Jul-05 ensure that parts are not damaged or degraded during G G G G
shipping. Testing example: cross country shipment
Document and track issues (including part damage,

12 PA LS 3-Jan-06 30-Jul-05 resourcing, recycling, movement, opening removal, G G G G
Ergonomics, etc.) for resolution of issues and concerns.
For Volvo, all Logistics requirements in addendum 18a, are on

13 SI LR 3-Jan-06 30-Jul-05 G G G G Packaging and Material handling has been
time with a high quality of event
finalised between Rico and Volvo. Material Prashant
Packaging Standard finalized. Packaging Handling between Rico India to UK Gupta/
Overall SI LS 3-Jan-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) G Y G G G G Std. under discussion for air fright mode. warehouse is Rico's Responsibility and
Akinla
Karen
15-Oct-04 28-Feb-06
between UK warehouse to Volvo Plants is Kuhlmann
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Volvo's responsibility.
Copyright© 2001 Ford Motor Company Page 37 of 49 - 18. Packaging Specifications Printed: 05/08/2020
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Advanced Product Quality Planning - 18a. Logisitics (VCC Unique)
APQP Element Rating Checklist Logistics is the movement of material or parts from one location to another by the safest, quickest
18a Logistics - VCC and most reliable means available. The location may be internal or external, a building,
department or machine.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
D K Manjhi
There are NO major Logistics issues/inhibitors, that will create Rico to understand the requirements &
1 PA LS 3-Jan-06 30-Jul-05 Y Y Y G G G Rico to understand the Requirements Akinla / Prashant 15-Oct-04
an uncontainable risk now or in the foreseeable future. completed as per Timing Plan
Gupta
Ensure that procedures for data exchange according to

D K Manjhi
"Odette subset of EDIFACT D96A" has been implemented Rico to understand the requirements &
2 PA LR 3-Jan-06 30-Jul-05 Y Y Y G G G Rico to understand the Requirements Akinla / Prashant 15-Oct-04
and verified (DELFOR, DESADV, OTL corresponding to completed as per Timing Plan
Gupta
DESADV, multiple and flexible dock/gate).
Develop a flow chart showing how the communication and D K Manjhi

3 PR LR 3-Jan-06 30-Jul-05 system flow of the incoming delivery instruction data is Y Y Y G G G Flow chart for communication to be made AS PER PLAN Akinla / Prashant 15-Oct-04
received and processed. Gupta
Ensure that the VCC's material requirements are processed

D K Manjhi
with the same frequency as received and data is transferred
4 CP LR 3-Jan-06 30-Jul-05 Y Y Y G G G Rico to ensure To be ensured Akinla / Prashant 15-Oct-04
automatically and immediate to other systems and business
Gupta
processes. Accuracy check of orders.
Ensure that the label is fulfilling the VCC's demand according

to the subset of ODETTE and verified in regard to printer D K Manjhi
5 CP LR 3-Jan-06 30-Jul-05 quality of label, paper quality, content of label, label is directly Y Y Y G G G Rico to ensure To be ensured Akinla / Prashant 15-Oct-04
linked to advance shipping note (DESADV) and the systems Gupta
are able to handle S-, M- and G-packaging.
D K Manjhi
6 CP LR 3-Jan-06 30-Jul-05 Ensure that EDI is used for all deliveries including preseries. Y Y Y G G G Rico to ensure To be ensured Akinla / Prashant 15-Oct-04
Gupta
Ensure that days of sending call-off (DELFOR), time horizon D K Manjhi

7 CC LR 3-Jan-06 30-Jul-05 of the call-off and fixed period is confirmed with the receiving Y Y Y G G G Rico to ensure To be ensured Akinla / Prashant 15-Oct-04
plant. Gupta
8 PR LR 3-Jan-06 dd-mmm-yy Delivery precision target of 100% is accepted. G G G G G G
Develop a material flow chart 1. for the procurement process,

also describing the replenishment lead times from critical
suppliers, 2. for the production process, also describing the D K Manjhi
To be completed by Rico as per Timing
9 PR LR 3-Jan-06 30-Jul-05 lead times in production , interfaces with other functions and Y Y Y G G G Rico has to develop the Flow Chart Akinla / Prashant 15-Oct-04
Plan
management principals of physical flow (KANBAN, push/pull Gupta
etc.), 3. for the distribution process, lead times and physical
flow.
Ensure that a method of communication has been agreed D K Manjhi

10 CP LR 3-Jan-06 30-Jul-05 between VCC and supplier covering information of quantity Y Y Y G G G Agreement on meeting & communication To be decided by Rico as per Timing Plan Akinla / Prashant 15-Oct-04
deviations. Gupta
Verify that the reaction time from order to despatch does not
11 CP LR 3-Jan-06 dd-mmm-yy G G G G G G
exceed 24 hours
Ensure that targets exist regarding logistics performance,
12 PR LR 3-Jan-06 dd-mmm-yy delivery precision to customer, delivery precision from sub G G G G G G
suppliers and rating system of sub supplier.
Ensure that data exchange with sub suppliers have
13 PR LR 3-Jan-06 dd-mmm-yy G G G G G G
satisfactory lead time and is reliable.
Ensure that production planning parameters are adequate,
D K Manjhi
batch sizes (no of day's production), bottle necks identified,
14 CP LR 3-Jan-06 30-Jul-05 Y Y Y G G G To be ensured To be ensured by Rico as per Plan Akinla / Prashant 15-Oct-04
trough put time, administrative planning time, frequency of
Gupta
short and long term planning.
Develop a capacity plan, week by week, during project, D K Manjhi

15 CP LR 3-Jan-06 30-Jul-05 introduction and ramp up phase and when bought capacity is Y Y Y G G G Capacity Plan week wise To be made Akinla / Prashant 15-Oct-04
reached Gupta
16 CP LR 3-Jan-06 dd-mmm-yy Ensure that procedures exist for packaging availability G G G G G G
17 CP LR 3-Jan-06 dd-mmm-yy Ensure that the flexibility model is understood G G G G G G
D K Manjhi
Ensure that L-FMEA exist for risk assessment internally and Rico has to understand & Perform as per
18 CP LR 3-Jan-06 30-Jul-05 Y Y Y G G G L-FMEA has to ensure Akinla / Prashant 15-Oct-04
towards sub supplier Plan
Gupta
Copyright© 2001 Ford Motor Company Page 38 of 49 - 18a. VCC Unique Logistics Printed: 05/08/2020
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Advanced Product Quality Planning - 18a. Logisitics (VCC Unique)
APQP Element Rating Checklist Logistics is the movement of material or parts from one location to another by the safest, quickest
18a Logistics - VCC and most reliable means available. The location may be internal or external, a building,
department or machine.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Ensure that finished goods are adequate controlled, taking

into account: accurate stock control regarding part no,
19 CP LR 3-Jan-06 dd-mmm-yy quantity and location, FIFO, stock taking routines, G G G G G G
identification of products, quantities and status, consideration
of expire dates.
Ensure that adequate parameters are considered when stock

level of finished goods is decided, taking into account: D K Manjhi
20 CP LR 3-Jan-06 30-Jul-05 production flexibility and capacity, including batch sizes, Y Y Y G G G To be ensured will be ensured by Rico as per Plan Akinla / Prashant 15-Oct-04
packaging cost (standard and type bound), VCC requirements Gupta
(flexibility model) including overlapping industrial calendar.
Ensure that finished goods are stored in a covered and

21 CP LR 3-Jan-06 dd-mmm-yy G G G G G G
protected warehouse. Consider space.
Ensure "foolproof" deliveries of VCC/FMC common parts with D K Manjhi

22 CP LR 3-Jan-06 30-Jul-05 brand specific part numbers, packaging, labelling, despatch Y Y Y G G G To be ensured will be ensured by Rico as per Plan Akinla / Prashant 15-Oct-04
documentation. Gupta
Ensure that VCC packaging is managed with regard to

D K Manjhi
packaging instruction received and confirmed, packaging
23 CP LR 3-Jan-06 30-Jul-05 Y Y Y G G G To be ensured will be ensured by Rico as per Plan Akinla / Prashant 15-Oct-04
instruction adapted to production, updating of packaging
Gupta
instruction, adherence to packaging instruction
Ensure that ordering of VCC packaging is secured, packaging

D K Manjhi
are stored in a covered and protected warehouse. Note! The
supplier may not use VCC product packaging for internal use
Gupta
or use from sub supplier without prior written consent by VCC.
D K Manjhi
Ensure that distribution of empty packaging have been set up,
agreement (standard packaging), booking routines.
Gupta
D K Manjhi
Ensure capacity for loading and unloading and protected from
wind and rain.
Gupta
D K Manjhi
Ensure that despatch frequency, despatch days and window
are established with VCC.
Gupta
D K Manjhi
Verify that the DESADV is sent within one hour after transport
28 CP LR 3-Jan-06 30-Jul-05 Y Y Y G G G Verification of DESADV will be ensured by Rico as per Plan Akinla / Prashant 15-Oct-04
departure.
DK Gupta
Manjhi
29 CP LR 3-Jan-06 dd-mmm-yy Develop strategy for transportation of Dangerous goods G G G N.A. / Prashant
DK Gupta
Manjhi
Ensure the ability to handle daily despatches in accordance to
30 CP LR 3-Jan-06 30-Jul-05 Y Y Y G G G Time table has to be decided to be done Akinla / Prashant 15-Oct-04
a by VCC pre-set time table.
Gupta
D K Manjhi
Ensure that ordering routines at Lead Logistics Provider have
been established.
Gupta
D K Manjhi
Ensure label position according to Odette standard and
fixation of label without staples in the bar code.
Gupta
D K Manjhi
Ensure that normal transport and rush transport instruction
have been confirmed.
Gupta
D K Manjhi
Ensure packaging set up. Packaging defined and verified. Unit
load updated, packaging instruction produced and confirmed.
Gupta
D K Manjhi
Rico to understand the Volvo specific
Overall 3-Jan-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y Y G G G Logistics Requirements
Rico will ensure it as per plan Akinla / Prashant 15-Oct-04
Gupta
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 39 of 49 - 18a. VCC Unique Logistics Printed: 05/08/2020
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Advanced Product Quality Planning - 19. Production Trial Run (Internal and External Suppliers)
APQP Element Rating Checklist The Production Trial Run is a validation of the effectiveness of the manufacturing and assembly
process, using production tooling, equipment, environment (including production operators),
19 Production Trial Run - Internal & External Suppliers facilities and cycle times. Output of the Production Trial Run is used for Production Part Approval
Current Gate <J1> for the manufacturer.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Production Trial Run issues/inhibitors,

1 CP LS 3-Jan-06 30-Jul-05 that will create an uncontainable risk now or in the G G Y G G G
foreseeable future.
for the Production Trial Run including product engineering,
2 CP CP 1-Mar-05 dd-mmm-yy G G G G G G
process engineering, the plant, suppliers, quality, etc, as
applicable.
Use all appropriate available data (e.g. surrogate process,
3 CP CP 1-Mar-05 dd-mmm-yy etc.) to estimate predicted OEE levels for the production G G G G G G
process and further estimate capacity levels.
Determine any issues from the OEE analysis that could
prevent Run-at-Rate and capacity by the required date, and MS / Anil
4 CP CP 1-Mar-05 30-Jul-05 Y Y G G G G OEE analysis has to do . to be done by Rico as per plan 15-Oct-04 28-Aug-05
prepare a resolution plan for all issues. Note: An acceptable sharma
OEE is 85% or greater.
Conduct Production Trial Run using production facility, tooling,

equipment and personnel.
Conduct Production Trial Run using production operations

(e.g. Production operators, inspection, etc.)
MS / Anil
7 CP LR 3-Jan-06 30-Jul-05 Conduct Production Trial Run using production packaging. Y G G G Production Packaging has to finalise Packaging Discussion under Process Akinla 15-Oct-04 28-Aug-05
sharma
Conduct Production Trial Run producing latest engineering
level PSW-1 parts.
Conduct Production Trial Run using the Pre-Launch Control

Plan.
Verify operator and process instructions during Production

Trial Run ensuring that they can be performed as intended.
Establish Variability Reduction Teams (VRT) to work on

11 CP LR 3-Jan-06 dd-mmm-yy reducing build variation for new complex assembly issues G G G G
noted during the Production Trial Run.
Document issues noted during the Production Trial Run for

assignments and resolution prior to production.
Demonstrate to Ford, the ability to produce parts at line rate

(Capacity Verification) prior to the program's Job #1 date.
Typically this is completed 4 weeks before System Fill.
13 CP LS 3-Jan-06 dd-mmm-yy G G G G
(NOTE: High Impact suppliers require VC Buyer, Ford STA,
and MP&L sign-off approval. Non-High Impact suppliers are
to notify Ford of any issues identified).
MS / Anil
Overall CP LS 3-Jan-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G 4. OEE analysis has to do . 4. PPAP planned on 23-Mar-06
sharma
15-Oct-04
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 40 of 49 - 19. Prod'n Trial Run - Supplier Printed: 05/08/2020
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Advanced Product Quality Planning - 19. Production Trial Run (Ford Assembly Plant)
APQP Element Rating Checklist The Production Trial Run is a validation of the effectiveness of the manufacturing and assembly
process, using production tooling, equipment, environment (including production operators),
19 Production Trial Run - Ford Assembly Plant facilities and cycle times. Output of the Production Trial Run is used for Production Part Approval
Current Gate <J1> for the manufacturer, and "Open-To-Go" review for Assembly.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Production Trial Run issues/inhibitors,

1 LR LS 3-Jan-06 that will create an uncontainable risk now or in the
foreseeable future.
for the Production Trial Run including product engineering,
2 LR LR 3-Jan-06
process engineering, the plant, suppliers, quality, etc, as
applicable.
Conduct Production Trial Run using production facility, tooling

3 LR LS 3-Jan-06
and equipment.
Conduct Production Trial Run using production operations

4 LR LS 3-Jan-06
(e.g. Production operators, inspection, etc.).
5 LR LS 3-Jan-06 Conduct Production Trial Run using production packaging.
Conduct Production Trial Run using latest engineering level

6 LR LS 3-Jan-06
PSW parts.
Conduct Production Trial Run using the Pre-Launch Control

7 LR LS 3-Jan-06
Plan.
Verify operator and process instructions during Production

8 LR LS 3-Jan-06
Trial Run ensuring that they can be performed as intended.
Establish Variability Reduction Teams (VRT) to work on

9 LR LS 3-Jan-06 reducing build variation for new complex assembly issues
noted during the Production Trial Run.
Document issues noted during the Production Trial Run,
Finished Vehicle Reviews (conducted by GRC), and Fresh
10 LR LS 3-Jan-06
Eye Reviews for assignments and resolution prior to
production.
Demonstrate the ability to produce parts at line rate (Capacity
Verification) prior to the program's Job #1 date. Typically this
is completed 4 weeks before System Fill. (NOTE: High
11 LR LS 3-Jan-06
Impact suppliers require VC Buyer, Ford STA, and MP&L
sign-off approval. Non-High Impact suppliers are to notify
Ford of any issues identified).
Overall LR LS 3-Jan-06 Team's Overall Rating of this Element ( G/Y/R )
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 41 of 49 - 19. Prod'n Trial Run - Ford Printed: 05/08/2020
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Advanced Product Quality Planning - 20. Production Control Plan (Internal and External Suppliers)

The Production Control Plan is a written description of the systems for controlling parts and
20 Production Control Plan - Internal & External Suppliers processes during full production. This document is based on the Pre-Launch Control Plan.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Production Control Plan issues/inhibitors,

1 CP LR 3-Jan-06 30-Jul-05 that will create an uncontainable risk now or in the G G G G G G
foreseeable future.

for the development of the Production Control Plan which
includes members from the plant, design engineering, process
engineering, and quality, etc., as applicable, and list the team
members or appropriate contact names on the Production
Control Plan.
Develop the Production Control Plan using the latest Ford


those required for the Production Control Plan, and obtain
process and design engineering input and concurrence, as
applicable.
Carry over all identified Significant Characteristics (SCs) and

Critical Characteristics (CCs) from the Pre-Launch Control
Plan to the Production Control Plan. Additionally, items that Sc / Cc Identification From prelaunch Sc / Cc Identification will be done from MS / Anil
5 CP LR 3-Jan-06 30-Jul-05 G G G G Petrus 15-Oct-04
need to be monitored by special controls e.g. customer Control Plan prelaunch Control Plan sharma
issues, Recalls, Craftsmanship, etc.) must be included on the
Production Control Plan.
Define inspection plans for those material and engineering

specifications that require monitoring.
Verify gauges and test equipment are accurate, repeatable,

7 CP LR 3-Jan-06 dd-mmm-yy and reproducible with adequate discrimination using the AIAG G G G G
Include appropriate inspection sample sizes and frequencies

on the Production Control Plan.
Document process capability requirements, including

measurement procedures and techniques.
Ensure the Production Control Plan includes the "current

controls" from the P/DFMEA's that have not been sufficiently
improved in the new design or process, and which still require
monitoring in production.
Ensure that Reaction Plans specify corrective and

containment actions necessary to avoid operating out-of-
control or producing non-conforming products. (e.g. 100%
hand torque of non-capable processes.
Copyright© 2001 Ford Motor Company Page 42 of 49 - 20. Prod'n Ctrl Plan - Supplier Printed: 05/08/2020
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Advanced Product Quality Planning - 20. Production Control Plan (Internal and External Suppliers)

20 Production Control Plan - Internal & External Suppliers processes during full production. This document is based on the Pre-Launch Control Plan.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Give the customer the opportunity to review and approve the

Update Control Methods and Reaction Plans to address any

issues and Lessons Learned during the Production Trial Run,
including counter measures for known capability problems.
Note: Customer approval is required for inverted delta parts.
Sc / Cc Identification From prelaunch Sc / Cc Identification will be done as per MS / Anil
Overall CP LR 3-Jan-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) G G G G G G Control Plan plan from prelaunch Control Plan
Petrus
sharma
15-Oct-04 28-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
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Advanced Product Quality Planning - 20. Production Control Plan (Ford Assembly Plant)

20 Production Control Plan - Ford Assembly Plant processes during full production. This document is based on the Pre-Launch Control Plan.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Production Control Plan issues/inhibitors,

1 LR LS 3-Jan-06 that will create an uncontainable risk now or in the
foreseeable future.

for the development of the Production Control Plan which
includes members from the plant, design engineering,
2 LR LR 3-Jan-06
process engineering, and quality, etc., as applicable, and list
the team members or a appropriate contact names on the
Develop the Production Control Plan using the latest Ford

3 LR LS 3-Jan-06

those required for the Production Control Plan, and obtain
4 LR LS 3-Jan-06
process and design engineering input and concurrence, as
applicable.
Carry over all identified Significant Characteristics (SCs) and

Critical Characteristics (CCs) from the Pre-Launch Control
Plan to the Production Control Plan. Additionally, items that
5 LR LS 3-Jan-06
need to be monitored by special controls e.g. customer
issues, Recalls, Craftsmanship, etc.) must be included on the
Define inspection plans for those material and engineering

6 LR LS 3-Jan-06
specifications that require monitoring.
Verify gauges and test equipment are accurate, repeatable,

7 LR LS 3-Jan-06 and reproducible with adequate discrimination using the AIAG
Include appropriate inspection sample sizes and frequencies

8 LR LS 3-Jan-06
on the Production Control Plan.
Document process capability requirements, including

9 LR LS 3-Jan-06
measurement procedures and techniques.
Ensure the Production Control Plan includes the "current

controls" from the P/DFMEA's that have not been sufficiently
10 LR LS 3-Jan-06
improved in the new design or process, and which still require
monitoring in production.
Copyright© 2001 Ford Motor Company Page 44 of 49 - 20. Prod'n Ctrl Plan - Ford Printed: 05/08/2020
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Advanced Product Quality Planning - 20. Production Control Plan (Ford Assembly Plant)

20 Production Control Plan - Ford Assembly Plant processes during full production. This document is based on the Pre-Launch Control Plan.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
Ensure that Reaction Plans specify the corrective and

containment actions necessary to avoid operating out-of-
11 LR LS 3-Jan-06
control or producing non-conforming products. (e.g. 100%
hand torque of non-capable processes)
Update Control Methods and Reaction Plans to address any

12 LR LS 3-Jan-06 issues and Lessons Learned during the Production Trial Run,
including counter measures for known capability problems.
Overall LR LS 3-Jan-06 Team's Overall Rating of this Element ( G/Y/R )
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 45 of 49 - 20. Prod'n Ctrl Plan - Ford Printed: 05/08/2020
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Advanced Product Quality Planning - 21. Preliminary Process Capability
APQP Element Rating Checklist The Preliminary Process Capability study is a statistical assessment of the ability of the process to
21 Preliminary Process Capability produce product within specification. Refer to the AIAG Production Part Approval Process (PPAP)
manual for more details concerning the Preliminary Process Capability Study.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Preliminary Process Capability

1 CP J1 16-May-06 30-Jul-05 issues/inhibitors, that will create an uncontainable risk now or G G G G G G

Preliminary Process Capability requirements including
dimensional control, quality engineering, process engineering,
the manufacturing facility, tooling supplier, etc., as applicable.
Use the AIAG Production Part Approval Process (PPAP),

AIAG Statistical Process Control (SPC) Manual and/or
appropriate internal Ford procedures to perform the
Preliminary Process Capability requirements.
Establish a plan for performing process capability studies on

new or revised processes, Significant/Critical Characteristics Sc / Cc Plan Finalised. CRT agreement Mkj / Anil
4 CP CP 1-Mar-05 30-Jul-05 Y Y G G G G Plan for SC / CC Characteristics Petrus 15-Oct-04 30-Aug-05
(e.g. SC/CC's), torque and Powertrain High Importance signed. Sharma
Characteristic (HIC), etc.
Conduct initial Preliminary Process Capability or Gauge R & R

5 CP CC 11-Oct-05 dd-mmm-yy studies at the Tooling, Equipment or Gauge supplier and G G G G
correct any observed issues.
Identify any non-capable processes and develop a corrective

6 CP CC 11-Oct-05 dd-mmm-yy
action plan to achieve capability requirements.
Demonstrate correlation between sources of variation, product

7 CP CC 11-Oct-05 dd-mmm-yy G G G G
characteristics and/or downstream operations.
Perform Preliminary Process Capability studies after

installation in the part manufacturing plant, as documented in
the Pre-Launch Control Plan(s) and achieve a minimum
Pp/Ppk of 1.67 or as specified by the Customer.
For any situations (including torque) where a minimum Pp/Ppk

(short term) value of 1.67 or customer specified requirement,
9 LR J1 16-May-06 dd-mmm-yy cannot be reached at LR, develop a work plan to address
issues in preparation for a Cp/CpK (long term) value of 1.33 or
customer specified Cp/CpK, at Job #1 + 90 days.
8. Pp/Ppk study to be done for Additional 8. Pp/Ppk study done for Additional Mkj / Anil
Overall CP J1 16-May-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) Y Y G G G G Manufacturing Streem. Manufacturing Streem.
Petrus
Sharma
15-Oct-04 10-Oct-06
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 46 of 49 - 21. Prelim Process Capability Printed: 05/08/2020
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Advanced Product Quality Planning - 22. Product Validation Testing (Internal and External Supplier)
APQP Element Rating Checklist Production Validation Testing refers to engineering testing which validates that products made from
production tools and processes meet engineering standards/specifications. All Internal and
22S Production Validation Testing - Internal & External Suppliers External Suppliers to Ford are to complete Production Validation Testing as a requirement of the
Current Gate <J1> Part Submission Warrant (PSW).
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Production Validation Testing

1 CP LR 3-Jan-06 dd-mmm-yy issues/inhibitors, that will create an uncontainable risk now or G G G G G G

Production Validation Testing requirements including product
2 CP CP 1-Mar-05 dd-mmm-yy design, manufacturing engineering, part suppliers, tool G G G G G G
suppliers, plant quality, plant manufacturing engineering, etc.,
as appropriate.
Define the production test plan in the form of a Production

3 CP CC 11-Oct-05 dd-mmm-yy Validation Plan (PVP&R), Engineering Specifications (ES), G G G G G G
and/or Pre-Launch Control Plan, etc.
Identify the affected part/assemblies on the production test

plan.
Verify manufacturing readiness through a system review (e.g.

QOS Audit, Manufacturing Readiness Review, etc.)
Ensure that tests are conducted with parts generated from

Production Trial Run including parts from alternative paths
(i.e. in process repair/rework, and alternative manufacturing
processes).
Ensure that test data has been reviewed by the Production

Validation Team.
Initiate a Corrective Action Plan with assignments and conduct

8 CP LR 3-Jan-06 dd-mmm-yy
follow-up for any/all issues.
Ensure that Management has reviewed the Production

Validation results and signed-off, as appropriate.
Archive the Production Validation results for future lessons

learned.
For Volvo Define the Production test plan in the form of

11 CP CC 11-Oct-05 30-Jul-05 G G G G Production Test Plan has to submit to volvo Production test plan made Prashant 15-Oct-04
TR,DRWG,STD and/or Pre-Launch control plan etc
For Volvo Content (frequency and amount) of PV testing

12 CP LR 3-Jan-06 30-Jul-05 G G G G Agreement of PV testing in under process Volvo has no data. Confirmed by Volvo Jonas Prashant 15-Oct-04
during running production to be agreed upon
12.Agreement of PV testing in under
Overall CP LR 3-Jan-06 30-Jul-05 Team's Overall Rating of this Element ( G/Y/R ) G G G G G G process
Volvo has no data. Confirmed by Volvo Jonas Prashant 15-Oct-04 28-Aug-05
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 47 of 49 - 22. PV Testing - Supplier Printed: 05/08/2020
474860621.xls
Advanced Product Quality Planning - 22. Product Validation Testing (Ford Assembly Plant)

Production Validation Testing refers to engineering testing which validates that products made from
22F Production Validation Testing - Ford Assembly Plant production tools and processes meet engineering standards/specifications.
Current Gate <J1>
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major Production Validation Testing

1 CC LS 3-Jan-06 issues/inhibitors, that will create an uncontainable risk now or

Production Validation Testing requirements including product
2 CC CC 11-Oct-05 design, manufacturing engineering, part suppliers, tool
suppliers, plant quality, plant manufacturing engineering, etc.,
as appropriate.
Define the production test plan in the form of a Production

3 CC LR 3-Jan-06 Validation Plan (PVP&R), Engineering Specifications (ES),
and/or Pre-Launch Control Plan, etc.
Identify the affected part/assemblies on the production test

4 CC LR 3-Jan-06
plan.
Verify manufacturing readiness through a system review (e.g.

5 CC LR 3-Jan-06
QOS Audit, Manufacturing Readiness Review, etc.)
Ensure that tests are conducted with parts generated from

Production Trial Run including parts from alternative paths
6 CC LR 3-Jan-06
(i.e. in process repair/rework, and alternative manufacturing
processes).
Ensure that test data has been reviewed by the Production

7 CC LR 3-Jan-06
Validation Team.
Initiate a Corrective Action Plan with assignments and conduct

8 CC LS 3-Jan-06
follow-up for any/all issues.
Ensure that Management has reviewed the Production

9 CC LS 3-Jan-06
Validation results and signed-off, as appropriate.
Archive the Production Validation results for future lessons

10 CC LS 3-Jan-06
learned.
Overall CC LS 3-Jan-06 Team's Overall Rating of this Element ( G/Y/R )
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 48 of 49 - 22. PV Testing - Ford Printed: 05/08/2020
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Advanced Product Quality Planning - 23. Part Submission Warrant
Production Part Approval Process is the documented verification that the Internal or
APQP Element Rating Checklist External supplier meets all engineering design requirements and the process has the
23 Part Submission Warrant (PSW) capability to meet these requirements during an actual production run. The Part
Submission Warrant (PSW) is the final sign-off that the Production Part Approval Process
Current Gate <J1>
(PPAP) has been followed.
<CC>
<SC>
<PH>
<PA>
<PR>
<LR>
<LS>
<FS>
<J1>
Program Supplier
<SI>
(CP)
(ST)
Timing Timing
There are NO major PSW issues/inhibitors, that will create an

uncontainable risk now or in the foreseeable future. Note:
1 CP J1 16-May-06 dd-mmm-yy G G G G G G
Quality and Reliability Statement of Work (SOW) requirements
are/have been met.
the preparing all evidence for the PSW.
Prepare for the PSW using the latest Ford internal procedures
3 CP CP 1-Mar-05 dd-mmm-yy and/or the AIAG Production Part Approval Process (PPAP)
manual, as appropriate.
Plan, prepare, and set timing to the required elements of the
4 CP CP 1-Mar-05 dd-mmm-yy PSW so that it can be achieved at, or prior to, the Ford
Assembly Plant's Production Trial Run (1PP Build).
Ensure that PSW will be achieved and sufficient PSW material
will be delivered to the customer plant by the In Plant Date
(IPD) to support each Stamping Plant's and Assembly Plant's
material requirements. Note: Any PSW requirements not met
MUST be supported with an approved ALERT prior to
shipment.
Prepare for capacity verification evaluation by understanding
6 LR LS 3-Jan-06 dd-mmm-yy the specific requirements of the capacity verification (run-at-
rate) sign-off process.
Ensure that parts can be produced at line rate (Run-at-Rate)
7 LS J1 16-May-06 dd-mmm-yy before Job #1 (4 weeks before System Fill) including
validation of remaining cavities/tools/lines.
Ensure that all issues determined from the Preliminary
Process Capability Element, (Pp/Ppk <1.67) as well as, issues
determined in the build process which will prevent an ongoing
8 LS J1+ 16-May-06 dd-mmm-yy
capability of CpK of 1.33 at Job #1 + 90 Days, are addressed
with action plans and associated timing. These plans MUST
be reviewed and signed off by STA.
Ensure that PSW will be achieved and sufficient PSW material

will be delivered to the customer plant by the In Plant Date
(IPD) to support each Stamping Plant's and Assembly Plant's
material requirements. Note: For VCC any PSW
requirements not met MUST be supported with an approved
HPD prior to shipment
FORD
Phase 3 PPAP (PSW) to be sign Phase 3 PPAP (PSW) demonstrated to Ford Maninder
Overall CP J1+ 16-May-06 Team's Overall Rating of this Element ( G/Y/R ) G G G G G G off STA.
STA /
Singh
15-Oct-05 18-Oct-06
Petrus
16-May-06
18-Nov-03
18-Nov-03
19-Jun-03
13-Apr-04
11-Oct-05
5-Dec-02
1-Sep-04
1-Sep-06
1-Mar-05
3-Jan-06
3-Jan-06
Copyright© 2001 Ford Motor Company Page 49 of 49 - 23. Part Submission Warrant Printed: 05/08/2020
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Advanced Product Quality Planning Status Report (Pan Brand, Europe)

Supplier Code: EBL8A FPDS Milestone: <J1> Notice Level: 0

Decision taken for PCRs (#7 and #8) and PCR 5

3 Craftsmanship () () () () () () (G) (G) (G) (G) (G) N.A TO RICO

PCR's (2 nos.) underconsideration by Volvo , MS / Anil

Discuss with VOLVO Team DVP&R Tracking is

9. All proecss are being reviewed for MS / Anil

Sc/ Cc are to be defined by Volvo. Sc/ Cc are defined by Volvo. MS/Anil

Tooling order received for PCR 7 and 8.

Tolerance issues are being discussed in the Issue

12. SC/CC to be decided

Supplier Code: EBL8A FPDS Milestone: <J1> Notice Level: 0

7. Functionality & safety Check of equipment &

4. Review of KPC / KCC

Packaging and Material handling has been finalised

Sc / Cc Identification will be done as per plan from MS / Anil

Overall APQP Status Rating (GYR) R R G G G G

BUILD EVENT - PROTOTYPE

BUILD EVENT - PRODUCTION

Copyright© 2001 Ford Motor Company

RICO AUTO INDUSTRIES LTD.

Copyright© 2001 Ford Motor Company

Chief Engineer: PMT leader:

RISK INFORMATION (SITE, TECHNOLOGY, PROCESS, OTHER - HIGH IMPACT ??)

Copyright© 2001 Ford Motor Company

There are NO major Sourcing Decision issues/inhibitors, that

Ensure that the Supplier's Quality History is factored into the

Ensure that Assembly and Stamping Plants are aware of all

The Early Sourcing Target Agreement (ESTA) and Reliability

Copyright© 2001 Ford Motor Company

FPDS Timing Due Dates

Decision taken for PCRs (#7 and #8) and

Define the cross-functional team that will be responsible for

Develop a list of the key contact personnel within Ford and

Develop an "Action Matrix" from information requested by the

Analyze and understand appropriate Vehicle Benchmarking

Analyze initial system and component designs and

Analyze and understand Reliability and Quality Goals

Copyright© 2001 Ford Motor Company

FPDS Timing Due Dates

Use the Program's Timing Dates to create a plan for APQP

Prepare a Total Cost review for the applicable affordable cost

Understand the Capacity Planning Volumes as they are

Understand any related logistic requirements, (including

Understand the appropriate requirements of the Program's

Are all relevant contacts in place to enable Supplier

Develop a list of the key contact personnel within Ford and

Has a definition of 'Virtual Product Program' been

Copyright© 2001 Ford Motor Company

FPDS Timing Due Dates

Have the IT Technical aspects of the suppliers deliverables

Understand the Virtual PIMPAT requirements, i.e. CAD level

For PTO parts, have you received transmittal documents for

Copyright© 2001 Ford Motor Company

APQP Element Rating Checklist

Define the Program Attribute Teams (PAT) cross-functional

Participate and/or support Global Craftsmanship Gateway

Vehicle/Program Craftsmanship requirements, developed by