APQP Overview PDF

APQP
Process Training
Advanced Product Quality Planning
March 15, 2017
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APQP
Overview
Process Training
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Supplier APQP: APQP Overview APQP Process Training
Goal: Utilize a standard approach for advanced product quality planning that will
support the development of a product or service to satisfy the customer and fulfill
the AIAG APQP Standard.
PHASE 1 SUPPLIER SOURCING (GSM Procedure 7.2.2)
§ Not included in the APQP process
PHASE 2 PLAN & DEFINE (8 ELEMENTS)
§ [APQP2-1] Supplier kick-off meeting
§ [APQP2-2] Submit initial Supplier Characteristics Summary (SCS]
§ [APQP2-3] Complete and submit PFMEA
§ [APQP2-4] Develop capability study plan to include rational sampling
§ [APQP2-5] Submit gage plan (including concepts, designs, methods, fixturing and clamping,
etc..)
§ [APQP2-6] Define packaging specifications
§ [APQP2-7] Verification of supplier equipment, tool and gage purchase orders
§ [APQP2-8] Submit supplier plan for APQP management of sub-tier suppliers
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Supplier APQP: APQP Process Training
APQP Overview
PHASE 3 PROCESS DESIGN & DEVELOPMENT (5 ELEMENTS)
• [APQP3-1] Verify capital equipment with evidence
• [APQP3-2] Complete final production process flow diagram
• [APQP3-3] Complete and Submit Production Control Plan
• [APQP3-4] Submit Traceability Plan
• [APQP3-5] Submit Pre-Production Control Plan including EPC
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APQP Overview
PHASE 4 PRODUCT & PROCESS VALIDATION (7 ELEMENTS)
• [APQP4-1] Initiate Measurement System Analysis (MSA)
• [APQP4-2] Submit Appearance Approval (if required)
• [APQP4-3] Validate final packaging
• [APQP4-4] F1058 process audit initiation
• [APQP4-5] Supplier PPAP submission (GSM4-2) & Approval
• [APQP4-6] MQ1 samples due
• [APQP4-7] MQ2 samples due
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APQP Overview
PHASE 5 PRODUCTION & AQE TO SQE TRANSITION (3 ELEMENTS)
§ [APQP5-1] F1058 process audit closure
§ [APQP5-2] Run at Rate
§ [APQP5-3] Final Production Sign-off (AQE to SQE hand-off)
Outcome: A robust product quality planning process that meets the
Customer’s expectations
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APQP
Elements Table
Process Training
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APQP Elements Table - 11 categories APQP Process Training
Goal: The list of elements is the required subject matter to be adjusted in accordance to the risk
assessment
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APQP Elements selection APQP Process Training
Goal: The list of elements is the required subject matter to be adjusted in accordance to the risk assessment
ELEMENTS DESCRIPTION
▪ The Supplier APQP process addresses risk assessment in order to adjust resources and
activities accordingly.
▪ In total 8 different categories are defined :
PPAP Renewal – PPAP level based on program need
Bulk Materials – PPAP level 2
Catalog – Functional – PPAP level 2
Catalog - Non-Functional – PPAP level 4
Non Black Box Service Parts – PPAP level 2
OEM Directed Parts – PPAP level as agreed with OEM customer
Capacity Change w/ Additional Equipment/Tooling – PPAP level based on program need
Capacity Change w/o Additional Equipment/Tooling – PPAP level based on program need
▪ In addition, three categories are related to PPAP Level 3 with different level of risk from Low to
Medium to High
▪ In each category, a pre-selected list of elements are mandatory. In each category, a pre-
selected list of activities with AQE and SQE are mandatory to be performed. In any case, for
some special situation, the region may request more than requested at corporate level.
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APQP
Risk Assessment
Process Training
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APQP Risk Assessment APQP Process Training
Risk Assessment Guidelines
Goal: Use a common ranking of level of risk associated with each element being assessed
A risk is the combination of the probability of occurrence of a positive event (opportunity) or a negative
event (threat) and its impact on the objectives of the project. Based on our approach, the risk is seen as a
threat.
Ø Risk Level 0 (Low): Negligible or non-existent
Ø Risk Level 1 (Medium): Minor, project can continue but action plan recommended
Ø Risk Level 2 (Medium): Major, project obstacles possible and action plan necessary
Ø Risk Level 3 (High): Critical, project obstacles certain and Escalation necessary
Action plan should be documented in the open issues list
Outcome: Consistent Criteria used globally to ensure consistent risk rankings
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Goal: Identify the level of potential risk in the APQP process to deliver a Perfect Launch.
Definitions
• Risk - A risk is an uncertain event or a set of events which, if they occur, will have an effect
on the achievement of objectives.
• Internal Risk – Risks associated with the Customer, Program, Specifications, Technology,
Complexity/Interface, Reliability/Safety
• External Risk – Risks associated with specific supplier selected
• APQP risk assessment = Consolidation of Internal Risk (2) AND External Risk (3) assessment
Process Steps:
1. Evaluate Internal Risk
Ø Can be performed once the product drawings/specifications are available
Ø Team: PLPL, Buyer, AQE Supervisor, PE (input from PQ & Sales is welcomed)
2. Evaluate External Risk
Ø Performed after MAPP
Ø Team: PLPL, Buyer, AQE (input from PE, PQ & Sales is welcomed)
3. Determine APQP Risk level
Ø HIGH risk for internal OR HIGH risk external => part is at HIGH risk
Ø LOW risk for internal AND LOW risk for external => part is at LOW risk
Ø Others cases => part is at MEDIUM risk
Outcome: Identify appropriate level of review to ensure a Perfect Launch
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Internal Risk Assessment
Goal: Identify the level of potential risk associated with Customer, Program, and Part specific
elements impact on the APQP process to deliver a Perfect Launch
Inputs
1. Drawings & Specifications
2. Customer requirements & feedback
3. Program timing
4. Part & application requirements / complexity
5. Internal APQP risk assessment form (FXXXX)
Process
1. Gain feedback from cross functional team
Ø Team: PLPL, Buyer, AQE Supervisor, PE (input from PQ & Sales is
welcomed)
2. Evaluate each elements Risk
3. Calculate the internal risk assessment rating based on the
following:
Ø Only one Risk at Level 3 => part is at HIGH risk
Ø Any assessment with Risk at Level 0 OR at Level 1 => part is at
LOW risk
Outcome: Internal Risk rating documented and results used for APQP
Risk Assessment
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External Risk Assessment
Goal: Identify the level of potential risk associated with the selected supplier’s elements
impact on the APQP process to deliver a Perfect Launch
Inputs
§ MAPP
§ MCA
§ Past launch performance with selected supplier
§ External APQP risk assessment form (FXXXX)
Process
1. Gain feedback from cross functional team
Ø Team: PLPL, Buyer, AQE (input from PE, PQ & Sales is welcomed)
2. Evaluate each elements Risk
3. Calculate the External risk assessment rating is based on the
following:
Ø Only one Risk at Level 3 => part is at HIGH risk
Ø Any assessment with Risk at Level 0 OR at Level 1 => part is at
LOW risk
Outcome: External Risk rating documented and results used for
APQP Risk Assessment
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Final Risk Assessment
Goal: Calculate the APQP risk level based on the Internal & External Risk assessments
Inputs
• Completed Internal Risk Assessment
• Completed External Risk Assessment
Process
1. Worksheet auto calculates the APQP Risk level
Outcome: APQP Risk level defined for the part.
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SOURCING
Phase 1
Process Training
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APQP Element AQE 1-1: APQP Process Training
Manufacturing Capability Assessment (MCA)
Goal: Confirm a supplier is able to manufacture product according Nexteer's quality requirements
Inputs:
• Nexteer Supplier Requirements (NSR)
• Nexteer Terms & Conditions (T&C’s)
• Similar quotation on similar part and existing business
See nexteer.com Supplier
portal Doing Business with
Nexteer section
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Manufacturing Capability Assessment (MCA)
Process Steps:
1. Pre-manufacturing floor process walk by Nexteer
process/commodity expert for part being considered
2. MCA document template
3. Completed supplier MCA Self Assessment
4. MCA on site assessment completed by AQE and Buyer
(ECM, PQ, & PE, if available)
5. Green acceptance criteria is >=90%, Yellow is 67-89%,
Red is <67%
A. Before a Yellow or Red MCA supplier can be sourced, action plans
must be documented & agreed
B. Red MCA suppliers must be approved by Global Supplier Quality
Director before SQ Regional Mgr can approve the sourcing
portal Quality Documents 6. AQE uploads MCA file and value into Intelex based on
section for guidance supplier profile creation associated with DUNS number
Outcome: A supplier is verified as capable to manufacture product according
to Nexteer's quality requirements or an incapable supplier is disqualified.
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Manufacturability Assessment & Process Plan (MAPP- F1039)
(MUST use latest version from Nexteer website)
Goal: Assess a supplier’s ability to Inputs:
manufacture a specific part to Nexteer’s • Pre-reviewed drawing at least at Development level and
requirements (Quality, under revision control
Capacity, Timing….) • Current MAPP revision template sent to supplier
• Completed DSS available to supplier
• MAPP Section 6 program detail
• MAPP completed by supplier a minimum of 3 working
days prior to actual review
• RASIC matrix for Nexteer (RhodeS)
• Customer Requirements
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Manufacturability Assessment & Process Plan (MAPP)
Process Steps:
1. MAPP Review must have Buyer, in supplier region AQE,
PE, PC&L at a minimum (supported by other process
experts, Nexteer plant region AQE, etc...) with supplier
2. Supplier owns MAPP documentation process and
updates until final submission for Nexteer approval.
3. DocuSign MAPP required by PE, AQE, PC&L
portal Sourcing Documents
section for guidance
Outcome: A MAPP verified capable supplier meets Nexteer's quality
requirements or an incapable supplier is disqualified.
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APQP APQP Process Training
Sourcing Phase
Goal: Award business to the optimal supplier based on Quality, Price, Capabilities, and
commodity strategy.
Inputs:
§ MAPP
§ MCA
§ RFQ
§ F1054 Sourcing form
Process Steps:
1. Sourcing Process
Outcome: Supplier is notified of new business and APQP process begins
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APQP
Phase 2
Process Training
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APQP Element AQE 2-1 APQP Process Training
Supplier Kick-Off Mtg
Goal: Ensure all Quality/Cost/Delivery Nexteer requirements are communicated, understood,
& taken into account by supplier to guarantee a perfect launch
Inputs:
• MCA & MAPP
• Nomination Letter
• Nexteer Supplier Requirements (NSR)
• Nexteer Drawing
Process Steps:
1. Determine the PPAP Level (1-5), and explain what is expected for
each item
2. Review the Nomination Letter, validating the terms on which the
business was awarded on.
3. Review both Nexteer’s and Supplier’s Lessons Learned from similar
products and launches
4. Agree Upon Part Feature Terminology to improve communication
5. Develop initial Early Production Containment Agreement (EPC)
6. Document the items review using the Supplier Kick off Checklist
(Form XXXX)
7. Summarize the Kickoff Meeting for all attendees
Outcome: Nexteer and Supplier begin the APQP process fully aligned on
all of the expectations and requirements.
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Supplier Kick-Off Mtg – PPAP Checklist
Goal: All PPAP requirements are understood by the supplier, ensuring a successful submission.
Inputs:
• PPAP checklist & Instruction
• PPAP template files
• Signed MAPP
• Buyer uploaded in PMD
• Drawings & Specs :
• Pre-reviewed drawing at Development level and under revision control
• Additional customer requirements OEM Customer Requirements
• Need check with Plant QE • SPDP Appendix 11 – AIAG Checklist
• SPDP Appendix 13.2 – PFD (Process Flow Diagram) Form
• SPDP Appendix 13.3 – Process Failure Mode and Affects (PFMEA) Form
• SPDP Appendix 15 – Run at Rate Worksheet
portal Processes section for
PPAP checklist and template
files
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Supplier kick-off Mtg – PPAP Checklist
Process Steps:
1. AQE/PE/QE defined specific requirements (Customer/Nexteer) expectations for Supplier PPAP
2. Others requirements must be defined such as CQI-9, Customer Requirement, Material, ... if
applicable
3. AQE selects level of PPAP per AIAG standards (Level 1-5)
4. AQE distribute PPAP checklist to supplier.
5. Supplier acknowledges receipt of PPAP checklist and submits copy of checklist with documented
progress during gate review.
6. PPAP Checklist must be filed in the APQP Tracker System
7. Confirmation of deliverables and associated confidentiality level. In case of patented process, at
minimum an extract of PFMEA and Process flowchart is required to show every dimensions critical
related
8. MAPP open issues list in APQP open issue tracker and follow up during APQP
Outcome: Identified and agreed upon requirements (Customer/Nexteer) for
Supplier PPAP submission.
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Supplier Kick-Off Mtg – Nomination Letter Confirmation
Goal: Ensure all deliverables meet the program launch timing, quality and deliveries
Inputs:
§ Nomination Letter
§ Quoted Capacity from the Nomination Letter
§ Production Capacity Plan (Sec 1 of Run @ Rate form; appendix 15)
§ Run @ Rate Plan (Sec 2 of Run @ Rate form; appendix 15)
§ Key Date Information (Sec 6 of MAPP)
§ Supplier APQP Timeline (Sec 9 of MAPP)
§ Nexteer Program Timeline (CPI from PLL)
§ Supplier Investment Plan: List of (Equipment, Tooling & Gages) for critical items to meet capacity
requirements and the timeline to purchase them
Process Steps:
1. AQE confirms with supplier that Run@Rate is based on #shift, #hours and numbers of weeks per year.
Nexteer requirement is 240 days/year, 48 weeks/year, unless specified in the nomination letter.
2. AQE verifies Capacity by matching ALL of the information from the Inputs for Location, Timing, and
Capacity.
3. Any discrepancies will be noted, and addressed on the Supplier APQP Open Items List (Sec 8 of MAPP)
Outcome: Agreed upon planning, timing and capacity plan
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Supplier Kick-Off Mtg – Lessons Learned Transfer
Goal: To continuously improve and learn from previous launches
Inputs:
• Previous Lessons Learned from AQE/SQE
Ø Intelex system problem cases for all similar products
Ø Previous look across input from APQP engineer (Quality)
Ø AQE can get the look across from PE of this product from prototype level parts
• Previous Lessons Learned/Look Across Summary from supplier
Ø Supplier lessons learned from other region of all similar products
Ø Supplier previous lessons learned from other projects of all similar products
Process Steps:
1. AQE calls meeting to include PE/QE/Supplier to review previous issues, concerns or challenges from
similar product; use Input list.
2. All lessons learned must be identified/addressed in Design, PFMEA, and Control Plan.
3. Capture PTC's (Pass-Thru Characteristics), customer impacts, and spills
4. Any findings will be noted, and addressed on the Supplier APQP Open Items List (Sec 8 of MAPP)
Outcome: All possible lessons learned reviewed; items requiring action
are documented in open issues list.
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Supplier Kick-Off Mtg – Agree Upon Part Feature Terminology
Goal: Create and share common part feature terminology to prevent confusion
Inputs:
• Drawings & Specs from PE
Process Steps:
1. AGREE UPON PART FEATURE TERMINOLOGY between PE/AQE and Supplier to ensure common language
regarding part features across team members/functions
Ø Component model view or drawing labeled with
common terminology (names) for key features
Ø Nexteer PE or AQE provide document to share with
supplier so all parties can use common feature
terminology (names) when discussing design, control
and quality related to the component
2. PE marks up drawing and specification with terminology
Outcome: Suppliers understand Nexteer’s drawings & specs with common
terminology documented as a reference, especially for
more complex commodities.
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Supplier Kick-Off Mtg – Early Production Containment Agreement
Goal: Identify critical characteristics that require controls that need to be
validated in EPC
Inputs:
• Lessons Learned from above steps
• Prototype parts
• Drawings & Specs from PE, Product exploded images
Process Steps: • MAPP
1. AQE to define EARLY PRODUCTION CONTAINMENT (EPC) Plan for supplier with PE/QE/Supplier.
Ø Plan which details the component characteristics required for Early Production Containment, control method,
duration and exit requirements
Ø EPC plan must meet product, process and program requirements including visual appearance items (ex. thread
patch coverage and lead thread protection where applicable)
Ø Supplier develops and submits comprehensive EPC plan for AQE review and approval. Reference EPC Tracker
(F1075) .
See nexteer.com
Supplier portal
Processes section for
F1075
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Supplier Kick-Off Mtg – Early Production Containment Agreement
Process Steps Continued:
2. EPC represents Nexteer as the supplier's customer, so any NG (Not Good) parts found in EPC
is a serious matter. (NG parts treated with Customer impact urgency)
3. AQE emphasis to the supplier is important at this APQP phase such that EPC data must be
submitted to them on a weekly during startup and thru the AQE's formally approved EPC
exit.
4. Define and agree at this phase what the EPC period will be (based on time or quantities with
zero NG parts).
5. It is recommended that a final period of time (ex. last 30 days of a 90 day EPC period) be with
the production control plan sample sizes and frequencies in order to validate the PCP prior to
approving EPC exit.
6. Additional EPC characteristics can be added based on review of PFMEA, Control Plan,
Capability Studies, etc..
7. Use the EPC opportunity to further select boundary sample parts based on reject criteria.
8. Validate EPC characteristics prior to exit of EPC (Supplier shall not self exit).
Outcome: Supplier and Nexteer agree early in APQP on the characteristics,
controls, & frequency for EPC to ensure that the production control
methods are validated as effective
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Submit initial Supplier Characteristics Summary (SCS)
Goal: Documents the features requiring a capability study for PPAP
Inputs:
• Drawings, Specifications, and DSS from PE side
Process Steps:
1. Supplier to complete and submit SCS (F1039) to AQE (SCS items may be added based on PFMEA and Control Plan)
Ø Document which summarizes key features (QCL’s) or other feature(s) which require a high level of control or
process monitoring and states specification, initial process capability an; d supplier control method.
Ø Complete initial SCS document. This step only requires the initial list of key components and dimensions to
be completed (Green section). Capability and control will be completed during later phases of APQP.
Ø Primary function of the SCS is to summarize only drawing QCI and QCL details and can be used for customer
review summaries. Additional features (PTC's, lessons learned, etc..) added by AQE/PE to MAPP Section 3 or
Control Plan for special controls, sample size or frequency inspections or capability studies are to be
managed as part of PPAP submission and are not required in this SCS summary.
Outcome: Identify key features which need special controls or monitoring.
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Complete and submit PFMEA
Goal: Ensure the high severity items and high RPN’s are mitigated for the development of the
control plan
Inputs:
• DSS or DFMEA severity levels from PE
• PFMEA Ranking Sheet (Severity &
Occurrence & Detection)
Ø Refer to F1043
• PFMEA template (AIAG format or equivalent)
• Past Problem Case History & Lessons
Learned
• Preliminary Process Flow Diagram from
MAPP
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Complete and submit PFMEA
Process Steps:
1. Supplier completed PFMEA with Severity, Occurrence and Detection rating for all dimensions
2. AQE/PE/QE review with supplier; minutes should include attendees, dates and key issues discussed
Ø All drawing dimensions identified on PFMEA
Ø With DSS Summary: DSS rankings dictate level of required control and inspection. Review PFMEA severity
rankings and Control Plans and inspection levels based upon prescribed DSS rankings
Ø Without DSS: Nexteer PE provides DFMEA severity levels (including for Black/Grey Box Supplier Designs) to
ensure alignment with PFMEA and Control Plans. Review of PFMEA rankings and Control Plan control and
inspection levels based upon DFMEA severity levels (including for Black/Grey Box Supplier Designs)
Ø Ensure that severity numbers match on the DFMEA and PFMEA
Ø Occurrence ratings are based on past problem cases, accumulated experience, and lessons learned following the
AIAG standards.
Outcome: PFMEA is aligned with the DSS/DFMEA and inputs are available for
the Control Plan development.
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Develop Capability study plan to include rational sampling
Goal: Agreement of how to collect representative parts to validate the process capability of all
the value streams
Inputs:
• Supplier Characteristic Study - SCS from above steps
• Machine/Tooling/Cavity information from supplier
• MAPP
Process Steps:
1. Defined plan which details features that require capability study (reference MAPP) and details plan for
collecting parts, sample size, sub-grouping and process interactions (include sub-tier consideration)
Ø Supplier to use information from MAPP and feedback from AQE to develop Capability Study Plan and submit to
AQE
Ø Refer to or seek out I&CIM expertise, as necessary, for more complex manufacturing value streams (ex. Multiple
die cast machines feeding multiple machining centers with multiple tombstone fixtures. Statistically determined
process combinations and calculations for part flow do not always require a standard sample size and
subgrouping at each process step to validate capability for the overall process to Nexteer's requirements)
Outcome: All features requiring capability studies are identified and
agreed to.
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Submit Gage Plan
Goal: To ensure the gages and methods developed for PPAP and production meet expectations
prior to PPAP submission
Inputs:
• Drawings & Specs from PE
• Approved MAPP
• SCS from AQE
• Proposed gage list (From AQE2-1) Supplier Investment Plan ( Equipment, Tooling & Gage) from supplier
• NSR gaging guidelines
Process Steps:
1. Supplier develop Gage Plan defining method for measuring component features, performance and/or
properties. Gage concept design to be included for complex or non-standard gages
2. Supplier to reference part drawing, DSS, MAPP and SCS and provide detailed plan for measurement
methods. PE and ME input for design interface and manufacturing application consideration.
3. Define supplier/Nexteer gage correlation: not required, duplicate gauging or correlation study. For
correlation study required, it must be coordinated with Nexteer Manufacturing Plant
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Submit Gage Plan
Process Steps:
4. Experts discussion is mandatory with software alignment to perform similar automatic
measurement (optical or tactile CMM)
5. Obtain agreement on gage plan (including concepts, designs, methods, fixturing and clamping, etc.)
6. Non-standard gage drawing approved by PE, AQE, Lab (requires PE, AQE, Metrology Lab signature)
7. Complete MSA (Measurement System Analysis) Plan
8. List dimensions and identify supplier gaging method, identify Nexteer gaging method, identify
dimensions requiring correlation and identify gages requiring correlation
9. Consider duplicate gage needs that may have been missed at MAPP time, and include receiving
plant inspection personnel early on to ensure measurement method and resultant correlation is not
a roadblock at PPAP submission or later in production.
Note: Supplier's ISO/TS certification needs to include gage manufacturing if they are proposing to build their own
gages.
Outcome: Best gage solution identified and agreed to in order to ensure
the measurement results are accurate and correlate between Nexteer and
the supplier.
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Define Packaging Specifications
Goal: Ensure the parts are protected during shipment and arrive in the desired format
(Qty, Orientation, etc…)
Inputs:
§ Packaging specification ("Nexteer Automotive Global Packaging and Shipping Manual Packaging and
Shipping Standards for Production Parts")
§ Nexteer pre-designed packaging as directed by PC&L, when applicable, and clarified in MAPP reviews
See nexteer.com
Supplier portal
Processes section for
Shipping & Labeling
guidance
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Define Packaging Specifications
Process Steps:
1. Packaging specification captured in Supplier Packaging Information
form (SPI), supplier submit SPI to Nexteer Buyer See comments in SPI form and link
to guide supplier’s input: Supplier
2. Supplier, Nexteer PCL and PE agree upon packaging design Packaging Information (SPI)
requirements

3. SPI completed by supplier and approved by PC&L (requires PC&L
signature)
4. Packaging trial plan requirements are created during technical
discussions among PC&L, Nexteer Plant and AQE. This is then shared
with Suppliers for the APQP Element AQE4-3 (Validate Final Packaging)
5. Signed SPI submitted by supplier to AQE as part of APQP
documentation and also submitted with supplier PPAP package (see
F1020-x PPAP Check Sheet 17e.)
6. Approved SPI uploaded by AQE as part of PPAP package to Parts
Management Database (PMD)
Outcome: Best packaging solution identified and agreed to in order to
protect parts and meet the Nexteer plant specific requirements.
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Verification of supplier equipment, tool and gage purchase orders
Goal: Critical path of every long lead time equipment & tools & gages are verified and program
is funded for contracted capacity.
Inputs
▪ Capacity plan from supplier
▪ Supplier Investment plan from supplier (Quantity and Timing)
▪ Purchase Order (P.O.) from Nexteer Buyer
▪ Nomination letter from Buyer (If incremental capacity is planned, it must be documented on the
nomination letter)
▪ MAPP section 10 (Capacity Plan) from AQE
▪ Machine planned cycle time from supplier
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Verification of supplier equipment, tool and gage purchase orders
Process Steps
1. Supplier provides Purchase Order(s) (P.O.) evidence for critical acquisitions for AQE/SQE
review and verification in accordance with the timing plan
Ø Equipment
Ø Tooling
Ø Gages
2. Compare Supplier Capacity Plan to signed Nomination Letter along with any approved
Incremental Capacity Plans
3. Confirm P.O. received by the vendor and current lead-time meet program requirements
Outcome: All critical & long lead-time Equipment, Tooling, & Gages have
been verified ordered on time and timing meets the program timing.
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Submit supplier plan for APQP management of sub-tier suppliers
Goal: Confirm Nexteer supplier is deploying APQP with their respective supplier and
communicating Nexteer requirements
Inputs
• Sub-tier List with Risk Assessment
• Sub-tier Supplier Process Flow Diagram (as applicable)
• CQI’s-x (as applicable)
• Special Characteristics Summary highlighting dimensions controlled by sub-tier suppliers
• Nexteer Supplier’s sub-tier APQP plan & Timing
Process Steps
1. Verify Nexteer’s supplier sub-supplier APQP Process is robust and comprehends Nexteer requirements.
2. Verify Nexteer’s Supplier tracks and verifies the quality systems and performance of its suppliers.
Ø Sub-tier List Ø Sub-tier Process Flow Diagram
Ø Sub-tier Audit plan Ø Sub-tier APQP/PPAP plan
Ø Material lead times in Supplier Timeline Ø SCS to sub-tier supplier (as required)
Ø CQI’s (as required)
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Submit supplier plan for APQP management of sub-tier suppliers
3. Where applicable, review Black/Grey Box Supplier Designs to ensure alignment with Nexteer's Tier 1
Supplier PFMEA and Control Plans, through to the final sub-supplier.
4. Verify that major milestones for their sub-tier suppliers are included on Nexteer’s supplier's program
timing plan
Ø Raw Material Lead times
Ø Long lead time items (equipment tooling, gages, etc....)
Ø PPAP
Ø Run at Rate
5. Determine which sub-tier suppliers require on-site visits from Nexteer
Ø Frequency of visits (especially suppliers with critical characteristics)
Ø Timing
Outcome: Sub-tier supplier’s launch is monitored and issues are addressed proactively to ensure a perfect
launch at Nexteer’s supplier.
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APQP Gate Review 2 APQP Process Training
Plan & Define
Goal: Verify that the APQP project is on track by completing a management review of
objective evidence for all required phase elements.
Inputs:
• List of required phase elements as determined by APQP risk level
• Objective evidence for each element completed
• May be hard copy or online documents
• Nexteer program timing and supplier timeline
• Knowledge of changes to program, part design or supplier’s plan
• Copies of previous internal and external risk assessments
• Phase 2 gate review form
Process Steps:
1. Identify the required functional participants based on risk
2. AQE Supervisor schedules all the gate review meetings based on Supplier
APQP timing agreed to in Supplier Kick-off meeting
3. Document the attendance on the gate review form (Suppliers should
attend all Gate Reviews)
4. Complete the drawing status and change request sections of the form
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Plan & Define
5. Review the objective evidence provided by the AQE for each element and assign a status as follows:
Ø Green – Element is complete, with evidence shown of detail that aligns with risk (e.g. meeting notes, onsite
review if required, detailed process documentation)
Ø Yellow – Requires minor changes, or lacking sufficient detail for assigned risk
Ø Red – Element not started or seriously late, jeopardizing program timing. Obvious lack of rigor or detail in the
evidence provided.
6. Document any significant changes at Nexteer or the supplier on the gate review form .
7. Document any critical pending requirements on the gate review form.
8. Identify any completed elements from a previous phase that must be reviewed again due to changes
identified during this gate review.
9. Review and update the internal and external risk assessments based on the findings of the gate review.
10. Gate review rating is automatically calculated based on elements ratings, drawing status, & ECR status
Ø Schedule follow up review(s) if the gate review status is not green.
Ø Escalate any significant changes, critical pending requirements or resource constraints to higher level Supplier
Quality or GSM management.
Note: Successful completion of the phase gate review is not required to begin work on elements that belong to later APQP
phases. However, all gate reviews must be complete with a green status before the AQE may transfer the part to an SQE.
Outcome: APQP elements all meet expectations and critical issues are
escalated and resolved timely
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APQP
Phase 3
Process Training
45
APQP Element AQE 3-1: Verify capital equipment with evidence APQP Process Training
Goal: Confirm the supplier is meeting timeline requirements and has the required
equipment in place for Run @ Rate on site at their manufacturing facility
Inputs:
▪ Nomination letter and Buyer Parts Management Database
approved incremental capacity plan (PMD)
(if supplier will not have full capacity at PPAP)
▪ Machine planned cycle time
http://www.nexteer.com/supplier-portal/processes/quality/
46
Inputs continued:
▪ MAPP section 10 http://www.nexteer.com/supplier-portal/processes/sourcing/
47
Process Steps:
1. AQE confirms (actually see with their eyes) machines, tools and gages are at the manufacturing
location. Use photos, videos, Skype.
2. AQE confirms the number of machines and the planned cycle time meets the contracted capacity
3. Supplier completes Run @ Rate Plan and Capacity Plan
4. AQE reviews the Supplier’s staffing plan and confirms that it matches the timeline and will be
completed ahead of PPAP, Run @ Rate, and SOP
Outcome: AQE verified that the Supplier has complete capacity at their
facility to meet Customer required volume.
48
APQP Element AQE 3-2: Complete final production process flow diagram APQP Process Training
Goal: Document additional details that were not included on the original simplified
production process flow diagram as well as any modifications or improvements
Inputs:
▪ Design Severity and Sensitivity; DSS (from PE; Product Engineer and/or PLL)
49
APQP Element AQE 3-2: Complete final production process flow diagram APQP Process Training
Inputs continued:
▪ Process Flow Diagram Plan (MAPP section 4)
http://www.nexteer.com/supplier-portal/processes/sourcing/
50
APQP Element AQE 3-2: Complete final production Process Flow Diagram APQP Process Training
Inputs continued:
▪ Completed PFMEA
Process Steps:
1. AQE confirms that Process Flow Diagram created by the supplier
clearly and completely describes production process steps and
sequence of operations.
Ø Both Incoming material and shipping considerations must be
included
Ø Hidden factories have to be shown in the PFD: rework, check
out of the line, bypass process.
Ø PFD is to be done Dock to Dock, take into account handling and
storage and shall include sub contracted operations
Ø QCL’s are to be labeled at the correct steps in the
manufacturing process
Outcome: A completed and Approved (by AQE) Final Production Process Flow
Diagram ready for PPAP submission and representing the intended manufacturing
process that will meet Nexteer requirements.
51
APQP Element AQE 3-3: Complete and Submit Production Control Plan APQP Process Training
Goal: Document expected long term controls based on PFMEA inputs and EPC
(Early Production Containment) to ensure quality performance is achieved
Inputs:
• Production released drawing &
specifications
• DFMEA (Supplier) / Design Severity
and Sensitivity (DSS) used and
Provided by Product Engineer – PE
• MAPP (from Buyer/PMD)
• Process Flow Diagram (Reference
APQP Element: AQE3-2) & PFMEA
(Reference APQP Element: AQE2-3)
52
Process Steps:
1. Compare DSS (or DFMEA), PFMEA, and Process Flow Diagram to determine inspection locations,
frequency and gage of dimensions, and ensure Severity is consistent through all documents.
2. Seek process expert review, agreement, and Sign-off for all CL!, CL2, & CL3 features per 3.2.5 Process
Expert Sign-Off Procedure
a) The list of commodities and respective process experts can be found at:
https://drive.google.com/drive/folders/0B2lA98OHdwoUSFFwb1lIWUVqZmM?usp=sharing
b) If the commodity does not have a process expert, the SQ supervisor must review the applicable line
items on the control plan
NOTE: Verify if there is an approved x1331 where applicable for any deviations from DSS requirements
that cannot meet G1331 guidelines.
Outcome: Completed and approved Production Control Plan that
includes QCL’s that match PFD and PFMEA
53
Process Steps:
1. Compare DSS (or DFMEA), PFMEA, and Process Flow Diagram to determine inspection locations,
frequency and gage of dimensions, and ensure Severity is consistent through all documents.
2. Seek process expert review, agreement, and Sign-off for all CL!, CL2, & CL3 features per 3.2.5 Process
Expert Sign-Off Procedure
a) The list of commodities and respective process experts can be found at:
Global Commodity Assignment by Buyer and Supplier Quality
b) If the commodity does not have a process expert, the SQ supervisor must review the applicable line
items on the control plan
NOTE: Verify if there is an approved x1331 where applicable for any deviations from DSS requirements
that cannot meet G1331 guidelines.
Outcome: Completed and approved Production Control Plan that
includes QCL’s that match PFD and PFMEA
54
APQP Element AQE 3-4: Submit Traceability Plan APQP Process Training
Goal: Ensure that a Traceability Plan mitigates the potential impact of non-conforming parts
Inputs:
• Drawing and Specification requirements
• Nexteer Supplier Requirements (NSR) http://www.nexteer.com/doing-business-with-nexteer/
• G1783 Product Traceability http://rhodes.nexteer.com/eng/edcc/html/cat1/global/glse1700.htm
55
APQP Element AQE 3-4: Submit Traceability Plan APQP Process Training
Inputs continued:
▪ Part size/shape/function for part marking (Reference Part Drawing)
▪ Manufacturing process / Expert lessons learned
(Examples: stamping, machining, die casting, etc.. (Reference Process Flow Diagram)
Process Steps:
1. Define acceptable level of traceability required Notes:
based on DSS and NSR ▪ Photos of traceability with
2. Identify traceability format Nexteer plant will decoder/explanation legend for PPAP, PPAP Check
receive, i.e. 2D bar code, laser etched numbers, ▪ ECR (Engineering Change Request) tracking
cavity number, shipping label, etc. number (if required) to update drawing to allow
3. Identify marking method, i.e. laser, dot matrix, cavity for individual part marking
number, label printer, etc. ▪ Confirmation that traceability plan meets
4. Identify points for variation, i.e. machines, fixtures, Nexteer Plant Operations’ expectations
cavities, shift, day, etc.
5. Include traceability on both PFMEA and Control Plan
6. Submit traceability plan that documents “HOW” the
traceability system will function to minimize the
exposure to defects (singular versus lot control).
7. Request drawing update for any changes related to
traceability
Outcome: Documented and Approved (by Product Engineer
and receiving Nexteer Plant) Traceability Plan
56
APQP Element AQE 3-5: Submit Pre-Production Control Plan including EPC APQP Process Training
Goal: Ensure that all supplier process controls are effective and the reporting of
non-conformances meet Nexteer’s expectations
Inputs:
▪ Production Control Plan (Reference APQP Element AQE3-3)
▪ DSS – Design Severity and Sensitivity (from Product Engineer)
▪ DFMEA (from Product Engineer, used to create DSS)
▪ PFMEA (Reference APQP Element AQE2-3) Notes: (Reference Supplier Kick-Off Meeting)
1. Documented Pre-Production Control Plan
Process Steps: 2. In case of a patented/proprietary processes, at a minimum an extract
of the production control plan is required to show every critical
1. Create a Pre-Production
dimension inspection gage and frequency.
Control Plan based on the 3. Where no critical characteristics or QCL’s exist on a drawing, the AQE
Production Control Plan, should identify characteristics or features for increased sample size
DSS, DFMEA and PFMEA and frequency. (Example: Pass-thru characteristics)
with a level of control in 4. EPC data must be submitted to AQE on a weekly/production run
basis.
accordance with Severity, 5. Define and agree at this stage what the EPC period will be (based on
Detection and Occurrence time or quantities with zero Non-Conforming parts).
from the PFMEA 6. It is recommended that a defined period of time (for example; last 30
days of a 90 day EPC period) be with the production control plan
2. Utilize pre-production sample sizes and frequencies in order to validate the PCP prior to
control plan for all parts approving EPC exit.
(MQ1, MQ2, etc..) 7. Formal notification from AQE to Supplier is required to close EPC
8. EPC needs to include label scanning verification at Supplier
Outcome: Completed Pre-Production Control Plan with EPC
(Early Production Containment)
57
Process Design & Development
Inputs:
Process Steps:
58
Process Design & Development
evidence provided.
59
APQP
Phase 4
Process Training
60
Initiate Measurement System Analysis
Goal: Qualify the measurement system prior to capability studies and PPAP
Prevent measurement discrepancies from impacting PPAP or serial production
Inputs:
Step#1: COMPLETE
• Drawing + DSS from PLM at production release MEASUREMENT
SYSTEM ANALYSIS
• Supplier Control Plan
• See requirements in NSR section 4.10 for samples
distribution used for MSA
• Engineering recommendation of measurement
Step#2: PRODUCT
• CMM program (if existing)
DIMENSION
CORRELATION
• Supplier protocol / method of measurement Step#3: GAGE
CORRELATION /
• List of dimensions and a column identifying CALIBRATION
supplier gaging method, a column identifying
dimension requiring correlation (AQE2-5)
61
Initiate Measurement System Analysis
Process Steps:
1. COMPLETE MEASUREMENT SYSTEM ANALYSIS (MSA gage study)
Ø Demonstrate Repeatability & Reproducibility (R&R)
Ø Minitab is recommended to collect and to present visually results
2. PRODUCT DIMENSION CORRELATION
Ø Ensure product measurement is equivalent between supplier and Nexteer laboratory
Ø Correlation must be conducted on the representative samples (cavities for instance) and with the
final equipment (CMM tactile or optical for instance). Samples must be identified and results are
verified. Any gap must be identified, analyzed and corrected if necessary
3. GAGE CORRELATION / CALIBRATION
Ø Ensure duplicate gages are equivalent between supplier and Nexteer incoming/laboratory
Ø When calibration is required, it should be defined supplier and agreed by Nexteer Lab
Outcome: A passed & verified Measurement System Analysis to ensure data
reliability at supplier and at Nexteer
62
Submit Appearance Approval
Goal: Gain agreement with Nexteer and customer on subjective visual requirements
Inputs:
Note: This element is only applicable to cosmetic visual items
▪ OEM Customer's requirements (especially for subjective items)
▪ Boundary samples
Process Steps:
1. Compile OEM on cosmetic items and flow down to supplier
2. Transform subjective items into specific or documented values with tolerances (grain, size
of acceptable burrs, number of defect per surface unit, etc.). Request Engineering support
for innovative solution of measurement.
3. Obtain supplier agreement through a defect library, called Appearance Approval Report
(AAR)
4. Build (when possible) boundary samples, identify them, keep them available at supplier
5. Transfer this proposal to final OEM
6. Organize discussion(s) until final OEM and supplier approval
Outcome: Transform cosmetic items into measurable value and gain OEM approval
63
Validate final packaging
Goal: Ensure that final packaging is compliant to Supplier Packaging Instruction (SPI) and to
manufacturing site
Inputs:
• Supplier Packaging Instruction
• Supplier Packaging Trial Plan (from AQE2-6)
• This Element is linked to the Element AQE 2-6: Define Packaging Specifications
Shipping & Labeling guidance
64
Validate final packaging
Process Steps:
1. Confirm the supplier proposal respects Nexteer’s requirements, based on Supplier
Packaging Information (SPI ) document populated by the supplier and in accordance with
the PC&L
2. Validation with real package, with representative parts in real conditions of transportation.
This validation includes the complete transportation value stream (warehouse-sea
shipment-warehouse-railway-warehouse-truck-warehouse).
3. Label on pallet and on carton/plastic/metallic boxes with the associated bar code system is
also part of this validation
4. Have supplier send label prior to shipment to verify Nexteer can read the barcode.
Labeling Requirements
Outcome: Obtain PC&L approval with signature (electronics or scanned
document) based on the released SPI document
65
F1058 process audit initiation
Goal: Evaluation of production readiness (equipment, documentation, operators) for launch, SQE
awareness of the process, and identification of any open issues requiring closure prior to the
responsibility shift to SQE
Inputs:
▪ Drawing + DSS + Specifications ▪ MCA results
▪ Supplier PFMEA + Process Flow + Control Plan ▪ PFD
▪ Supplier manufacturing process(es) ▪ EPC records
▪ Traceability Plan ▪ Operator Instructions
▪ SCS ▪ Gage records
▪ P.O. for samples ▪ Non conforming parts records
▪ Capacity planning (volume & timing) ▪ Preventative Maintenance records
▪ CQI-x audits (if applicable) ▪ All equipment, tools, gages & spare parts
▪ F-1058 Audit Form ▪ Approved SPI form & label
▪ Part Risk Level ▪ Operator(s)/Training Records & Documentation
▪ Supplier Self Assessment of F-1058
66
F1058 process audit initiation
Process Steps:
1. F1058 process audit initiation means to detect in advance non conformity and situation at risk in the
supplier process. This element is requested to ensure that the element “AQE5-1 F1058 process audit
closure” to be closed correctly the first time.
2. The “F-1058 – Supplier Process Production Readiness Audit Form” is the form to use and the action
plan is populated accordingly.
Quality guidance
Outcome: Identify risks and address process issues prior to PPAP, MQ1 and MQ2
samples; closing gaps by Nexteer SOP.
67
Supplier PPAP submission & Approval
Goal: Validate product & process compliance to Nexteer's requirements
Inputs: Process Steps:
▪ Drawings/Specs production released in PLM 1. COMPLETE PPAP BUILD
▪ PPAP Checksheet Ø Supplier performs a controlled PPAP Production Run
▪ PPAP Checksheet Instructions Ø Quantity as defined in the Nexteer Supplier Requirements
Ø Supplier's intended manufacturing location on production
intent equipment/tooling, at production rates with
▪ ALL PPAP documents in the expected production operators - incorporating the full production flow
electronic format (NSR 4.3) diagram and control plan
▪ Traceability plan 2. APPROVED PPAP DOCUMENTATION PACKAGE BY AQE TO PRODUCE
MQ1 & MQ2 SAMPLES
Ø AQE reviews PPAP package (Refer to "Golden PPAP" in
Procedure Matrix – Training Tab
Ø PPAP package approval including all elements of PPAP
(depending of the chosen categories of risk, see “Required
Elements to complete versus categories”)
Ø The “F1020 PPAP Checksheet” form is completed to
summarize the PPAP status
68
Supplier PPAP submission & Approval
Inputs: 3. SHIP PPAP PARTS TO NEXTEER PLANT
• PPAP P.O. Ø Guarantee deliveries from supplier to Nexteer in mass
production conditions: process, packaging,
Ø Nexteer Manufacturing Address
transportation, warehouse(s), up to the Nexteer
• AQE approved PPAP checksheet/documentation production line (Use X3483, PPAP Label)
4. PPAP APPROVAL BY LEAD NEXTEER USING PLANT
Ø Nexteer lead using plant verifies PPAP submission
through dimensional verification, PTRs, etc.
Ø Nexteer lead using plant approves PPAP
▪ PPAP Production Parts
Ø Notify supplier of approval
▪ Nexteer Materials Lab Report
Ø Upload signed PSW to PMD
▪ PPAP in PMD
Ø Nexteer lead using plant rejects PPAP
▪ PE Approval in PMD
Ø Lead plant uploads rejection and notifies AQE
▪ EP (if required) Ø AQE works with supplier to fix rejected items
and resubmit corrected items
Ø AQE Processes IRW if using rejected parts
Outcome: Part Submission Warrant (PSW) approved and signed by Nexteer Lead
Using Plant (Send signed copy to supplier)
69
MQ1 samples due
Goal: To ensure production intent parts are available for Nexteer’s machine run off on vendor floor
Inputs:
▪ Approved Supplier PPAP or IRW (see element AQE 4-5 Supplier PPAP submission & Approval)
▪ P.O. including MRD (Material Required Date), drawing and revision number, specific packaging and
location for MQ1 parts, if required
Process Steps:
1. Supplier sends sample parts produced for the purpose of Machine Qualification on a production
or fabrication machine at a Nexteer machine builder location
2. AQE ensures supplier shipping quantities meet MRD requirements
3. Supplier ships parts identified using PPAP label (X-3483) to Nexteer machine builder location
Outcome: MQ1 parts available for machine run-off at machine builder floor.
70
MQ2 samples due
Goal: To ensure production parts are available for machine run off at Nexteer
Inputs:
▪ Approved Supplier PPAP or IRW (see element AQE 4-5 Supplier PPAP submission (GSM4-2) & Approval)
▪ P.O. including MRD (Material Required Date), drawing and revision number, specific packaging and
location for MQ2 parts, if required
X3483
Global Sample and PPAP Label
Process Steps:
1. Supplier sends sample parts for the
purpose of Machine Qualification on a
production or fabrication machine at a
Nexteer Manufacturing location. (If not
already PPAP approved, follow Global
Sample and PPAP Label Instruction -
X3483)
2. AQE ensures the supplier is
shipping quantities meet MRD
requirements
Outcome: MQ2 parts are PPAP approved with a signed PSW, shipped to the
appropriate Nexteer plant, and are available for Production Trial Runs and Nexteer
Customer PPAP submission
71
Product & Process Validation
Inputs:
Ø May be hard copy or online documents
Process Steps:
72
Product & Process Validation
evidence provided.
73
APQP
Phase 5
Process Training
74
F1058 Process Audit Closure
Goal: Evaluation of supplier production readiness (equipment, documentation, operators) for launch.
SQE gains awareness of the process, and identification of any open issues requiring closure prior to the
responsibility shift from AQE to SQE
Inputs:
• F1058 open item list (APQP Element
AQE4-4, F1058 process audit initiation)
Ø This should include the Supplier’s
original action plan, timing, as well as
current closure status
Ø This should also include Supplier
evidence of issue closure
See nexteer.com
Supplier portal
Quality section for
F1058 Process Audit
file
75
F1058 Process Audit Closure
Process Steps:
1. AQE sends F1058 form to supplier or directs
them to the file on the Nexteer supplier
portal (as shown below)
See nexteer.com Supplier portal
Quality section for F1058 Process
Audit file
2. Supplier completes the Cover Sheet, the
Check Sheet Expanded and all appropriate
process specific worksheets in advance of
the AQE & SQE onsite verification audit.
(see instruction worksheet, as necessary)
3. AQE & SQE (recommended as part of
transition) complete the on site Supplier
audit to verify status and launch readiness
4. No RED items are allowed for launch.
Yellow status is OK to launch. Both Yellow
and Red items require immediate corrective
actions (escalate to Supplier leadership and
Program team, as necessary.)
Outcome: The supplier’s production readiness is verified for launch. SQE
Is familiar with the supplier’s process. Any open issues have been identified that require
closure prior to the responsibility shift from AQE to SQE
76
Run at Rate
Goal: Ensure the supplier’s manufacturing process meets the contracted capacity and identify any
potential issues & risks
Inputs:
• Supplier’s Appendix 15 Run at Rate Plan from APQP
Element AQE 3-1
• Supplier’s Nomination Letter from Buyer (the only
allowed incremental capacity agreement)
• F1058 Launch Audit result (APQP Element AQE 5-1)
• Review of APQP Element AQE 3-1 (verify capital
equipment) to determine level of risk for supplier to
meet requirements.
COMMENTS:
• If a documented agreement exists (i.e. Nomination
Letter) for an incremental capacity plan, a separate
PPAP and Run at Rate is required for each phase.
• On existing part changes that require a Run at Rate,
the activity becomes the responsibility of the SQE to See nexteer.com
conduct Run at Rate. Supplier portal
• Reference Appendix-24 for Run at Rate Exempt Quality section for
products not requiring a formal run at rate, and select Appendix 15 Run at
this option in PMD for R@R Status. Rate
77
Run at Rate
Process Steps:
1. Supplier submits their Capacity Plan and Run at
Rate Plan to AQE from APQP Element AQE 3-1
portal Quality section for
Appendix 15 Run at Rate
78
Run at Rate
Process 1 Process Steps:
Process 2 1. Conduct and document Run at Rate (AQE to invite
SQE and Plant Quality):
Ø High Risk - AQE on-site (others optional)
Process X
Ø Medium Risk - AQE on-site (others optional)
Ø Low Risk - Supplier Self-Assessment
2. Supplier completes Process # Actual Run Data
worksheets (tabs) for each process step during on
See nexteer.com
site or self-monitored run.
Supplier portal Quality
section for Appendix 3. The Run at Rate Summary Data worksheet will
15 Run at Rate auto fill from the Capacity Plan and Process #
Actual Run Data worksheet(s) or tabs
4. A Run at Rate should last, at a minimum, the
number of hours required to produce one day
worth of Nexteer Automotive production at
Maximum Scheduled Volume (from Buyer or
Program Launch Leader). This length must be
agreed to by the AQE/SQE.
79
Run at Rate
6. AQE determines if the Run at Rate Summary
worksheet data passes or fails Nexteer’s
requirements based on the color coded
result in columns AI and AJ on the worksheet.
Green=Pass, Red=Fail
7. AQE and Supplier agree on Pass/Fail result
and complete and sign R@R Status Form.
8. If the supplier’s daily capacity is less than
40%, the R@R could be considered for
Run@Rate exemption. A R@R exemption is
the responsibility of the AQE/SQE to
document and a SQ Supervisor/Manager to
approve and sign.
See nexteer.com
Supplier portal Quality
section for Appendix 15
Run at Rate
Outcome: The supplier’s manufacturing process along with their sub-tiers is verified
to meet the contracted capacity (on Appendix 15 form). Any potential issues & risks are
identified while the production process is stressed (quality, handling, material flow,
gaging, bottle neck, safety)
80
Final Production Sign-off (AQE to SQE hand-off)
Goal: Ensure perfect launch readiness and transfer lead role to SQE for seamless production
Inputs:
• Pre-Production Control Plan (PPCP)
• Production Control Plan (PCP)
• EPC inspection data (F1075) from all pre-production runs
(template on Nexteer.com Supplier portal)
• In process control plan inspection data from all pre-production
runs
• Boundary Samples confirmed in process
• Problem Cases from this supplier’s launch
• Problem Cases from similar parts and other suppliers
• 3 Legged 5 Whys reviewed
• PFMEA
• F1058 Process Audit (APQP Element AQE 5-1: F1058 Process
Audit Closure) See nexteer.com
• Run at Rate result (APQP Element AQE 5-2: Run at Rate) Supplier portal
Quality section for
• Supplier's completed Special Characteristics Summary (SCS) F1075 EPC
with evidence of Ppk requirements achieved for all critical Workbook Template
features
81
Final Production Sign-off (AQE to SQE hand-off)
Process Steps:
1. AQE/SQE should compare PPCP to supplied EPC data to confirm all items are being inspected
and there are no defects in EPC for the past 30 days.
2. AQE/SQE should compare EPC data to in process production data, and require any control
plan improvements to prevent bad parts from being produced and/or shipped to Nexteer.
3. AQE/SQE confirms any Problem Case issued did not reflect EPC items and all Problem Cases
are closed in Intelex
4. AQE/SQE confirms 3 Legged 5 Why addresses root causes and systemic issues with irreversible
corrective actions in place and documented in PFMEA and Production Control Plan
Ø The supplier should update their PPAP for changed PFMEA and Production Control Plan
5. Supplier shall only exit from EPC with AQE/SQE approval
Ø Supplier submits written request (ex. Email) to AQE/SQE to exit EPC
Ø Formal notification (ex. Email) from AQE/SQE to Supplier closing EPC
Ø Exit can be either by specific EPC item or as an overall EPC exit approval.
6. Gate 5 review requires both AQE and SQE to be involved to close out APQP and to transition
from AQE to SQE
Outcome: The supplier is verified as ready to Go Live, the AQE and SQE close out the
APQP, and transition of lead responsibility moves from the AQE Launch phase to SQE
Seamless Production phase.
82
Production & AQE to SQE Transition
Inputs:
Process Steps:
83
Production & AQE to SQE Transition
evidence provided.
84
APQP APQP Process Training
Summary
Goal: Utilize a standard approach to produce a product quality plan, which will
support the development of a product or service that will satisfy the customer
Inputs:
§ AIAG APQP Standard
§ Trained AQE’s
§ Process that remains flexible enough for all applicable circumstances while ensuring that the intent is
achieved
Process Steps:
§ Thoroughly complete all elements in Phases 2-5 (Note: documentation required in English)
§ Supplier owns APQP activities
§ AQE owns Nexteer’s interest for a thorough and timely APQP – Extreme ownership!
§ Gate Reviews are scheduled and held based on the program timing … not completion of the elements
§ Each element is reviewed in detail during the appropriate gate review for accuracy and completeness
Outcome: APQP elements all meet expectations, critical issues are
escalated and resolved timely, and a perfect launch is achieved
85
Thank You
86

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