Process No: 

QP/NPM/03

Process : Activity Planning

Revision History

Details of revision

Issue DCR Prepared Reviewed Approved

Date Rev No.
No. No. By By By
(Mention Page No. of revision)
15-03- Revised to include Nadcap 

8              0              Manjula
2016          requirements                                                                                  3249 Ragini NA
                       Patil
     
              

Revised to include take approval

07-10- Manjula
8 1  from VP operations after each
3274 Ragini NA
2016 Patil

 phase of  APQP .  

Procedure modified by including 

06-03- Manjula
8 2 all APQP phase wise requirements 
3280 Ragini NA
2017 Patil

to cater MACE requirement.

1."Process objective"  is revised to cover product development

activity.from receipt of order to SOP at customer end.
2. APQP matrix is revised for plant 
location change (D)
3.Plan vs Actual reason for delay capturing 
01-06- added in all the phases. Manjula
8 3 3282 Ragini
NA
2017 4.In case of process Design, prepare proto Patil

 FMEA is added in Phase 2 

01-03- Revised to include that conduct stencil validation  even

Manjula
8 4 3287 Ashwani NA
2019 if the stencil is given by the customer(Step 3)
Patil
01-07- Procedure upgradation and Format correction
Manjula Savitha
9 0 3302 Darshan

2020
Patil
Ramesh

01-02- Savitha
9 1 Revised based on the ERP Next Module 3306 Sindhushree MMP
2022 Ramesh
ISSUE No. 09
Rev No: 01
 Process No:  QP/NPM/03
ISSUE No. 09

Process : Activity Planning Rev No: 01

                      COMPETENCE

                                            PROCESS
M/C, TOOLS
Process Objective: :To ensure that all design and development activities Knowledge on
are identified, planned and  Implemented in order to achieve defects.
  a.Product
free product on time which is applicable to New product, similar part,   b.Mfg and Testing Process
ECN/PCN and Plant location change starting from receipt    c.On CAD
PC of order to SOP at customer end.   d.Competency Requirement
Process owner :Head Engg

PHASE 1- PLAN AND DEFINE PROGRAM-INPUTS                               OUTPUTS

  a. Review all Documents

  b.Study the part Development
APQP FF NPM 09
  c.Collect the product benchmark data
INPUTS TGR/TGW FF NPM 11
  d.Review customer inputs and Requirement
CIRA FF NPM 02
PHASE 1 - PLAN AND DEFINE PROGRAM-OUTPUT NEXT
Product Design Risk Analysis FF NPM 08
  a. Define Quality Goals PROCESS

Input PFD FF NPM 14

  b.Define Product capability ,Process capability & Cost target

Customer Gerber Review FF NPM 17

  c.Conduct Gerber review

Item Master FF NPM 18

Purchase Order   d.Create Item master Process
BOM FF NPM 19
with Delivery   e.BOM  verification and Conformation
FMEA FF NPM 21
Design
PREVIOUS   f.Ensure CIRA & RISK Analysis
PROCESS
Schedule DFM FF NPM 22
  g.Identify product obsolescence ,Product recycling, 
DFA FF NPM 23
PHASE 2 PRODUCT DESIGN AND DEVELOPMENT
Activity DFT FF NPM 24
  a.Prepare Design FMEA, Drawing & Product Specification
Planning        b.Order & Procure the new Equipment
Control Plan  FF NPM 26
Drawing Specification  FF NPM 27
  c.Conduct Evaluation
Configuration Functional Baseline FF NPM 61
  d.Prepare Configuration functional Baseline
SPWI FF NPM 47
PHASE 3 -PROCESS DESIGN AND DEVELOPMENT
OQC Checklist FF NPM 54
  a.Review of Quality systems and update document
  b.Review process flow chart ,PFMEA MEASUREMENTS

  c.Identify test plan and Inspection & Test coverage Analysis

  d.Prepare OQC checklist & Packaging Specification Time to release BOM from CRP
METHODS   e.Conduct trail and approval for Gauge Number of instances of FMEA revision
  f.Review product file and Revist the process document Number of instances of Control Plan revision
  g.Prepare MSA Study Number of PFC pending for product /process validation
PHASE 4 -PRODUCT AND PROCESS VALIDATION Action plan pending for risk mitigation
Process Flow Chart  QP/   a.Conduct product trail Yield in Pilot lot
NPM /03   b.Do production verification and packaging evaluation Total number of Configuration files
EHS Procedures-   c.Conduct configuration management audit Number of NC in Configuration audit /Audit pending to close
QP/EHS/01   d.Compile PPAP Document Actions identified in risk & opportunities
,02,03,04,0,06,07 &  09.   e.Revisit risk analysis The needs and expectations of Interested parties
  f.Signoff Quality Planning. Paper Consumption
PHASE 5 - FEEDBACK ASSESSMENT AND CORRECTIVE Accidents/Incidents
ACTION Training conducted
  a.Review feedback from Customer TGR/TGW
  b.Revisit the Process Document 
     a)FMEA
     b)Control Plan
  c.Review all phase 5 activities 
EHS Requirement
 Process No:  QP/NPM/03
ISSUE No. 09
Process : Activity Planning Rev No: 01

A) Definition :
Product quality planning is a structured method of defining
and establishing the steps necessary to assure that a
product satisfies the customer. The goal of product quality
planning is to facilitate communication with everyone
involved to assure that all required steps are completed on
time.

B)Identify BU,BU head,project manager,APQP owner,cross

functional team for the project and prepare project FF OPM 38

Commercial, SBU,
organisation chart FF OPM 38 with roles and When PO received
Projects
responsibilities.Get approval from director operations in the
organization chart.

C) Enter the details of BU,BU head,project manager, FF NPM 09

1st day of CRP

customer key contact person,APQP owner and cross NPM-Executive
receipt
functional team including suppliers in APQP FF NPM 09.

D) Classify the product as new part, similar part, Changed

product & plant location change in FF NPM 09. FF NPM 09

1st day of CRP

NPM-executive
receipt
Note: FF NPM 09 - APQP for Expalantion on project
classification.

E) Identify whether the product is to be covered under

configuration management if configuration management 1st day of CRP FF NPM 09

NPM-executive
item, include the same in annexure-A to FF NPM 09 - receipt
configuration management plan.
F) Study customer documents. Identify the safety, statutory FF NPM 09

Within 3 Days of CRP

and regulatory requirements if any. Enter the details in CFT
receipt
APQP FF NPM 09.

G) Understand the customer requirements/Expectations

and assess the feasibility of the proposed design, Within 3 Days of CRP FF NPM 09

CFT
performance requirements and manufacturing process. receipt
Enter the details in APQP FF NPM 09.

H) Make an APQP timing plan to record the customer

required date and kaynes planned start date for proto
samples,production trial run,regular production,customer
lVP date (if applicable),customer HVP date (if applicable) Within 3 Days of CRP FF NPM 09

CFT
and customer SOP date (if applicable).Record the details in receipt
APQP FF NPM 09. Make sure that the customer required
quantity is also recorded. Get the Timing plan approved
from TOP management

I) Define the key targets  related to productivity, quality, FF NPM 09

Within 3 Days of CRP

cost, delivery, safety and morale. Record the details in CFT
receipt
APQP FF NPM 09.

J) Discuss with other internal team and prepare schedule

for team to team in meeting. Conduct team to team in As per APQP FF FF NPM 09

meeting as per the schedule once in a month and record APQP Owner NPM 09
FF OPM 41

the details in APQP FF NPM 09. Minutes the meeting FF Once in a Month
OPM 41 in ERP run # 3749

K) Identify the training needs related to the product. Define

the training description, training schedule, faculty, FF NPM 09

nominees. Complete the training as per schedule and As per APQP FF FF HRM 19

CFT
record the details in APQP FF NPM 09. Ensure the training NPM 09
record FF HRM 19 for each nominees, also entered in
ERP. 
 As per APQP FF FF NPM 09

L) Identify the members for concern resolution team and CFT

record the details in APQP FF NPM 09. NPM 09

M) Identify the concerns and schedule for a meeting with

concern resolution team whenever concerns arised. FF NPM 09

Discuss the issues with concern resolution team time to As per APQP FF FF OPM 41

CFT
time and close the concern. Record the details in FF NPM  NPM 09

09 - APQP. Minutes the meeting FF OPM 41 in ERP run #

3749

N) Schedule for a meeting with top management and

update all the details from step C to step N. Collect As per APQP FF FF NPM 09

feedback from top management and update FF NPM 08 APQP Owner NPM 09
FF OPM 41

APQP if applicable. Minutes the meeting FF OPM 41 after After each phase
each Phase

1. PHASE I - PLAN AND DEFINE PROGRAM 

1.1 Review all  Customer related commercial documents 

RFQ ,BFQ FF CRM 07customer ,PURCHASE ORDER, Consolidated Action
As per APQP FF items list required

CONTRACT REVIEW   FF CRM 16. Manufacturing Process Engineering 

NPM 01
feasbility and Risk analysis and JRQS and make
consolidation of Requirements

1.2 Carry out customer Input Review Analysis and Inward

the List of Tools/Jigs/Fixtures/Samples given by Customer FF NPM 02

As per APQP FF
in the CIRA FF NPM 02. Note: Keep the master sample in Process Engineering 
NPM 01
NPM with Identification Tag

1.3 Generate Query list FF NPM 03 for all clarification with Process Engineering  As per APQP FF FF NPM 03

customer  NPM 01
 As per APQP FF FF NPM 04

1.4 Carry out  the Risk analysis FF NPM 04 Process Engineering 

NPM 01

1.5 Study past development records and Record in  FF As per APQP FF FF NPM 05

Process Engineering 
NPM 05 NPM 01

1.6 Study Previous customer complaints, In house As per APQP FF

Process Engineering 
complaints and Supplier complaints (Kakotara sheet) NPM 01

2. PHASE II - PRODUCT DESIGN AND DEVELOPMENT

2.1 Prepare Item Master FF NPM 06 by Verifying with FF NPM 06

As per APQP FF
Datasheet for each Items, upload in ERP Run#: 3992, Process Engineering 
NPM 01
Upload Make & MPN

As per APQP FF FF NPM 16

2.3 Create BOM FF NPM 16 in .csv format and upload in

Process Engineering 
ERP.NEXT NPM 01

2.4 Conduct  BOM Analysis For all Aerospace & Defence

products and record in  FF NPM 17 as per WI NPM 02. Process Engineering  As per APQP FF FF NPM 17

Send the BOM analysis to the Customer and take NPM 01

approval. 

As per APQP FF
2.5 Conduct BOM Verification and release to procurement Process Engineering 
NPM 01

FF NPM 07
2.2 Generate the following parts list from ERP
FF NPM 08
1.List of LSL Items - FF NPM 07 As per APQP FF
  st o S te s 0 As per APQP FF
Process Engineering  FF NPM 09
2. List of specific consumables- FF NPM 08 NPM 01 FF NPM 10
3. List of Custom build items - FF NPM 09
FF NPM 11
 4.. List of MSD items - FF NPM 10
FF NPM 12
5. List of Critical items - FF NPM 11
FF NPM 13
6. List of Items Requiring Re-finishing - FF NPM 12
FF NPM 14
7. List of Gold removal items - FF NPM 13
FF NPM 15
8. List of EOL parts  - FF NPM 14
9. List of  Parts having Marks of conformity FF NPM 15

As per APQP FF
2.6 Collect IMDS from Suppliers / Manufactures Process Engineering 
NPM 01

2.7 Prepare Engineering Drawing FF NPM 18 in case FF NPM 18

As per APQP FF
customer doesn't provide Drawing  Process Engineering 
NPM 01
Do Balooning for all Drawings

2.8 Create  Incoming Quality Inspection Template for FF NPM 19

As per APQP FF
Custom built Items  Process Engineering 
NPM 01
Specific Inspection plan FF NPM 19

2.9 Link all other items to Existing Incoming Quality FF NPM 20

As per APQP FF
Inspection Template and Generate inspection BOM FF Process Engineering 
NPM 01
NPM 20

2.10 GERBER REVIEW

As per APQP FF FF NPM 21

Process Engineering 
2.10.1 Do Gerber review FF NPM 21 NPM 01
2.10.2  Identify the supplier for PCB , discuss the Gerber
As per APQP FF
with the prospective supplier and get their inputs and Process Engineering 
NPM 01
Record in Gerber review

2.10.3 Receive the panel Gerber from supplier if As per APQP FF

Process Engineering 
panalisation is required. NPM 01

2.10.4 Review with Technical team and  Finalise the Panel As per APQP FF
Process Engineering 
Gerber NPM 01

2.10.5 Link the gerber and specific drawings if any to the As per APQP FF
Process Engineering 
PCB part Number NPM 01

As per APQP FF FF NPM 22

2.11 Prepare Preliminary Process Flow Design FF NPM 22 Process Engineering 

NPM 01

As per APQP FF FF NPM 23

2.12 Prepare DFM Report  Process Engineering 

NPM 01

As per APQP FF FF NPM 24

2.13 Prepare DFA Report Process Engineering 

NPM 01
 As per APQP FF FF NPM 25

2.14 Prepare DFT Report Process Engineering 

NPM 01

2.15 Prepare special product/process characteristics FF As per APQP FF FF NPM 26

Process Engineering 
NPM 26 including appearance items. NPM 01

2.17 Identify the  programming  requirements for applicable FF NPM 28

As per APQP FF
manufacturing process  and update in List of Program FF Process Engineering 
NPM 01
NPM 28

As per APQP FF
2.17 Prepare list of TJF IMTE required for the product. Process Engineering 
NPM 01

2.18 Prepare specific work instruction's, CADs  and

supporting pin layout, Test Plan on FF NPM 29 wherever
applicable As per APQP FF FF NPM 29

Process Engineering 
Note 1: Ensure CAD is made for SMD (DNP Locations), TH NPM 01
Masking, TH Stuffing, Hand Soldering & Coating masking
Note 2: Ensure Supporting Pin Layout is made for Pick &
Place and Screen Printing stage if the PCBA is having both
the sides of components

As per APQP FF FF NPM 30

2.19 Prepare Specific CTQ FF NPM 30 if any Process Engineering 

NPM 01

As per APQP FF FF NPM 31

 2.20 Prepare layout inspection plan FF QAM 31 Process Engineering 

NPM 01

2.21 Prepare Specific test plan in Specific Work Instruction FF NPM 29

As per APQP FF FF NPM 32
in FF NPM 42 & Test report format in FF NPM 32 as per Process Engineering 
NPM 01
customer requirements

2.22 Prepare OQC checklist in FF NPM 33 in consultation As per APQP FF FF NPM 33

Process Engineering 
with QA & Upload OQC Plan NPM 01

As per APQP FF FF NPM 35

2.24 Prepare Packing Specification FF NPM 35. Process Engineering 

NPM 01

As per APQP FF FF NPM 34

2.23 Prepare Specific Dock Audit Check list FF NPM 34 Process Engineering 

NPM 01

As per APQP FF FF NPM 

2.24 Prepare Proto PFC by linking all above documents. Process Engineering 

NPM 01

2.25 Prepare Proto PFMEA- FF NPM 36 along with CFT As per APQP FF FF NPM 36

Process Engineering 
Members .Refer Guidelines for PFMEA WI NPM 04  NPM 01

2.26  Prepare prototype control plan FF NPM 37 with CFT As per APQP FF FF NPM 37

Process Engineering 
approach, review and approve. NPM 01

2.27 Prepare  process benchmark data FF NPM 38

considering the similar product  and update the data As per APQP FF FF NPM 38

Process Engineering 
relating to process capability, rejections, rework, scrap, NPM 01
yield, cycle times, productivity,.
2.28 Identification of required TJFE Equipments, tools, jigs,
fixtures, stencil, wave pallets, nozzles, supporting pin FF NPM 39

As per APQP FF
templates, feeders, Hand soldering,depanelizing jigs, Process Engineering 
NPM 01
depanelizing drill bits, ICT, FT, Coating jigs.) on List of tools,
jigs, Fixtures & Equipments FF NPM 39. 

2.29 Prepare list of IMTE/Checking Aids used for the As per APQP FF FF NPM 60

Process Engineering 
product FF NPM 60 NPM 01

2.30 Identification of specificTrolley/ESD trays/Magazine FF NPM 39

As per APQP FF
required to store and transfer the product from stage to Process Engineering 
NPM 01
stage in list of TJFE 

2.31 Indentification and Finalisation of poka yoke for TJFE

(Equipments, tools, jigs, fixtures, stencil, wave pallets, FF NPM 39

As per APQP FF
nozzles, supporting pin templates, feeders, Hand Process Engineering 
NPM 01
soldering,depanelizing jigs, ICT, FT.Coating  jigs.) on list of
Tools, Jigs, fixtures & Equipments

2.32 Identify the Manufacturing process where in Stress FF NPM 39

As per APQP FF
/strain measurement to be conducted and record in FF Process Engineering 
NPM 01
NPM 39

2.33 Revise Proto PFC, FMEA & Control Plan If required As per APQP FF FF NPM 27

Process Engineering 
and finalise the same NPM 01

2.34 Identification of Manpower Requirements, If Required, As per APQP FF FF HRM 20

Process Engineering 
Record in staffing plan FF HRM 20  NPM 01
2.35 Determine the requirement for New Production Line. If As per APQP FF FF EHS 24

Process Engineering 
Required Make floor plan in FF EHS 24 NPM 01

2.36 Prepare Stencil ordering checklist

FF NPM 40

As per APQP FF
2.36.1 Share the Finalised gerber to Approved stencil Process Engineering 
NPM 01
suppliers

As per APQP FF
2.36.2 Receive the check plot from supplier Process Engineering 
NPM 01

2.36.3 Review with Technical team and  Finalise the check As per APQP FF
Process Engineering 
plot NPM 01

As per APQP FF
2.36.4 Create stencil checklist FF NPM 40 Process Engineering 
NPM 01

2.36.5 Link Stencil check plot, DFM File & Pdf file , under As per APQP FF
Process Engineering 
the Stencil Part number NPM 01

As per APQP FF
2.36.6 Place Order  for Stencil Process Engineering 
NPM 01

2.37 WAVE PALETTE ORDERING 

FF NPM 40

As per APQP FF
2.37.1 Share the Finalised gerber to Approved  wave Process Engineering 
NPM 01
palette suppliers
 As per APQP FF
2.37.2 Receive the check plot from supplier Process Engineering 
NPM 01

2.37.3 Review with Technical team and  Finalise the check As per APQP FF
Process Engineering 
plot NPM 01

As per APQP FF
2.37.4 Create wave palette ordering checklist FF NPM 38 Process Engineering 
NPM 01

2.37.5  Upload wave palette check plot, DFM File & Pdf file As per APQP FF
Process Engineering 
under the Wave palette  Part number NPM 01

As per APQP FF
2.37.6 Place Order  for Wave Palette PM
NPM 01

As per APQP FF
2.38 Depanelizing Fixture Ordering Process Engineering 
NPM 01

2.38.1 Share the Finalised gerber to Approved  As per APQP FF FF NPM 40

Process Engineering 
Depanelizing suppliers NPM 01

As per APQP FF
2.38.2 Receive the check plot from supplier Process Engineering 
NPM 01

2.38.3 Review with Technical team and  Finalise the check As per APQP FF
Process Engineering 
plot NPM 01

As per APQP FF
2.38.4 Create Depanelizing  ordering checklist FF NPM 38 Process Engineering 
NPM 01

2.38.5  Upload Depnelizing ordering check list , DFM File & As per APQP FF
Process Engineering 
Pdf file, under the Depanelizing   Part number NPM 01

As per APQP FF
2.38.6 Place Order  for Depanelising fixture Process Engineering 
NPM 01

2.39 Hand soldering  Fixture

As per APQP FF
2.39.1 Share the Finalised gerber to Approved  Process Engineering 
NPM 01
handsoldering suppliers

As per APQP FF
2.39.2 Receive the check plot from supplier Process Engineering 
NPM 01

2.39.3 Review with Technical team and  Finalise the check As per APQP FF
Process Engineering 
plot NPM 01
2.39.4 Create Hand soldering ordering checklist FF NPM As per APQP FF FF NPM 40

Process Engineering 
40 NPM 01

2.39.5  Upload Hand soldering  ordering check list , DFM As per APQP FF
Process Engineering 
File & Pdf file under the Depanelizing   Part number NPM 01

As per APQP FF
2.39.6 Place Order  for Hand soldering Fixture Process Engineering 
NPM 01

2.40 ICT Fixture ordering

2.40.1 Share the Finalised gerber, CAD data, BOM and

As per APQP FF
schematic, Sample Board , Bare PCB to Approved  ICT Process Engineering 
NPM 01
Fixture  suppliers, In case sample Board, Bare board not
available, plan after proto

As per APQP FF
2.40.2 Create ICT Fixture  ordering checklist FF NPM 38 Process Engineering 
NPM 01

As per APQP FF FF NPM 40

 2.40.3 Upload  the Ordering Check list Process Engineering 

NPM 01

As per APQP FF
2.40.4 Send the ICT Fxiture ordering check list to supplier Process Engineering 
NPM 01

As per APQP FF
2.40.5 Place PO PM
NPM 01
2.41 FT Fixture Ordering
FF NPM 40

As per APQP FF
2.41.1 Share the Finalised gerber to Approved  FT jig Process Engineering 
NPM 01
suppliers

2.41.2 Share the Finalised gerber, CAD data, BOM and

schematic, Sample Board , Bare PCB, Test specifications to As per APQP FF
Process Engineering 
Approved   FT Fixture  suppliers, In case sample Board, NPM 01
Bare board not available, plan after proto

2.41.3 Review with Technical team and  Finalise the As per APQP FF

Process Engineering 
Requirements  NPM 01

As per APQP FF
2.41.4 Create FT ordering checklist FF NPM 38 Process Engineering 
NPM 01

As per APQP FF
2.41.5 Upload the FT Ordering check list Process Engineering 
NPM 01

2.41.6 Send the Approved FT  Ordering check list to As per APQP FF
Process Engineering 
supplier NPM 01

As per APQP FF
2.41.7 Place P.O PM
NPM 01

2.42 Coating Fixture Ordering

As per APQP FF
2.42.1 Share the Finalised gerber to Approved coating Process Engineering 
NPM 01
Fixture  suppliers
2.42.2 Review with Technical team and  Finalise the As per APQP FF
Process Engineering 
requirements NPM 01

As per APQP FF FF NPM 40

2.42.3 Create coating fixture  ordering checklist FF NPM 40 Process Engineering 

NPM 01

As per APQP FF
2.42.4 Upload the ordering check list in ERP Process Engineering 
NPM 01

2.42.5 Send the Approved wave ordering check list to As per APQP FF

Process Engineering 
supplier NPM 01

As per APQP FF
2.42.6 Place P.O Process Engineering 
NPM 01

2.43 Tool Autoinsertion 

As per APQP FF
Process Engineering 
2.43.1 Prepare the tool Drawing  NPM 01

As per APQP FF
2.43.2 Select the supplier for the tool Process Engineering 
NPM 01
 As per APQP FF
2.43.3 Raise P.O PM
NPM 01

As per APQP FF
2.43.4 Follow up for receipt  PM
NPM 01

2.44 Tool for drill bit for depanelizing

FF NPM 40

As per APQP FF
2.44.1 Identify the required Dia of Drill bit required and get Process Engineering 
NPM 01
approval from Technical Head

As per APQP FF
2.44.2 Order the required number of bits  PM
NPM 01

2.45 Other Tools, Jigs, fixtures  finalization

FF NPM 40

As per APQP FF
2.45.1 For all other Tools, Jigs and fixtures ensure that Process Engineering 
NPM 01
TJFE requirements is updated in FF NPM 40

As per APQP FF
2.45.2 Ensure other Tools, Jigs, Fixtures is ordered Process Engineering 
NPM 01

2.46 Equipment /IMTE Ordering

As per APQP FF
Process Engineering 
2.46.1 Review the list of TJFE NPM 01

2.46.2 Discuss with probable suppliers and shortlist

As per APQP FF
maximum 3 best choices and conduct detailed negotiation PM
NPM 01
with the suppliers
2.46.3 Consolidate all Equipment Specification including
complete technical specification, performance As per APQP FF FF ASM 03

PM
requirements, EHS requirements, Legal requirements etc. NPM 01
and update in the CAPEX form FF ASM 03 

2.46.4 Raise Capex FF ASM 03 giving full details. .

Conduct Capex Meeting and obtain approval from 3 Capex FF ASM 03
As per APQP FF FF ASM 04
Committee Members,  and Take approval from MD / PM
NPM 01
Director operations/CEO. Raise Revex FF ASM 04 if it is
less than Rs.5000/

2.46.5 Give a copy of approved  CAPEX/REVEX to  HOD

Maintenance who will allot CAPEX Number and update the As per APQP FF FF ASM 05

PM
CAPEX/REVEX Register FF ASM 05, also hand over a NPM 01
copy to Finance in order to arrange fund.

2.46.6 Place Purchase Order FF SCM 09 for the FF SCM 09

As per APQP FF
Equipment, including, if applicable, installation & PM
NPM 01
commissioning, on-site service, etc.

2.46.7 Follow up and get the Equipment from the supplier FF WHM 02

As per APQP FF
and manufacturer. Handover the documents to Stores, and PM
NPM 01
get FF WHM 02  GRIN prepared in ERP

2.46.8 Carry out  Asset Installation FF ASM 06 and Quality Assurance - As per APQP FF FF ASM 06

Updation of Master List KT-01 NPM 01

2.47 Sourcing of Custom built parts

2.47.1 Review list of custom built parts and identify the FF SCM 01

supplier from existing supplier list FF SCM 01. As per APQP FF FF NPM 09
SCM
NPM 01
In case existing suppliers are not competent identify new
supplier for the custom built parts. Update list of custom
built parts with FF NPM 09 with supplier details
2.47.2  Evaluate the identified supplier existing or new for FF SCM 07

As per APQP FF
their competency to develop each of the custom built SCM
NPM 01
parts.FF SCM 07

2.47.3 Conduct supplier audit wherever required as per WI Quality Assurance - As per APQP FF FF SCM 06

SCM 01 on FF SCM 06 KT-01 NPM 01

As per APQP FF FF SCM 09

2.47.4 Ensure all custom built parts are ordered  PM

NPM 01

2.48 Sourcing of Standard parts

FF SCM 10
2.48.1 Identify source for all standard parts including price Process Engineering 
As per APQP FF FF SCM 05
MOQ, SPQ and lead time and make a sourcing plan FF Buyer NPM 01
SCM 10 and do first time pricelink  FF SCM 05 in ERP

2.48.2 In case new suppliers are identified for standard As per APQP FF FF SCM 02
Buyer
parts conduct supplier evaluation on FF SCM 02 NPM 01

As per APQP FF FF SCM 09

2.48.3 Ensure that all standard parts are ordered Buyer
NPM 01

As per APQP FF FF SCM 09

2.48.4 Order specific consumables and request IMDS Buyer
NPM 01

2.48.5 Generate Product document configuration, review As per APQP FF FF NPM 41

 Process Engineering
and release the product file to the production NPM 01

2.48.6 Prepare Product Matrix, Review  and Release the As per APQP FF FF NPM 42
Process Engineering
product File to the Production  NPM 01

2.48.7  Train the Team about the product and update As per APQP FF FF HRM 19
Training
training record FF HRM 19 NPM 01

3. PHASE III - PRODUCTION

As per APQP FF FF WHM 02

3.1 Receive the Materials and Carry out Inspection   Process Engineering 
NPM 01

3.2 Receive the custom Built parts and carry out Incoming FF NPM 43
As per APQP FF
Layout Inspection and sample evaluation and  record in FF PM
NPM 01
NPM 43 

3.3 Work Order for Proto (Proto samples-1, 2, 3 (if

required)) As per APQP FF FF WHM 06
PM
3.01 Issue Work order for Proto build as per customer NPM 01
requirement
 As per APQP FF FF WHM 07
3.02 Issue Materials as per Kit List Process Engineering
NPM 01

3.03  If it is a new line, line release to be approved as per As per APQP FF FF NPM 44
Process Engineering
FF NPM 44. NPM 01

3.04 Conduct line side review (LSR) for readiness to start As per APQP FF FF NPM 45
Process Engineering
production using checklist FF NPM 45 NPM 01

3.05 Complete the Verification and validation of all As per APQP FF FF PRM 14

Process Engineering
Programs  as per the master list of Program FF PRM 14 NPM 01

3.06 Conduct TJFE - Stencil Validation, Wave Palette FF NPM 46

As per APQP FF
validation and all other Jig and fixture validation and record Process Engineering
NPM 01
in   FF NPM 46

3.07 Carry out Stress and Strain measurement for the Quality Assurance - As per APQP FF FF NPM 46
requried process KT-01 NPM 01

3.08 Conduct MSA studies for the required As per APQP FF FF NPM 46

Process Engineering 
gages/equipment. NPM 01
3.09 Conduct Specifc consumable qualification if required As per APQP FF FF NPM 47
Process Engineering 
and record in  FF NPM 47 NPM 01

3.10 Take the Reflow profile, Wave profile and selective FF NPM 48

As per APQP FF
soldering profile and Get the approval from Technical Head Process Engineering 
NPM 01
FF NPM 48 as per WI NPM 01 and WI PRM 14

3.11  Do product Process validation  for all the process

steps as mentioned in Process Flow Chart and  record the As per APQP FF FF NPM 49
Process Engineering 
observations /improvements inNew Product Process NPM 01
Validation Form IN FF NPM 49

3.12   Verify process performance and confirm whether

process design targets are met and enter the actual data in As per APQP FF FF NPM 38
Process Engineering 
Process Benchmark Data & Quality Goals-Target Vs NPM 01
Achieved FF NPM 38.

3.13 Prepare FAI Documents and obtain approval from QA As per APQP FF FF NPM 50
Process Engineering 
and submit to customer NPM 01

3.13 Prepare FAI Documents and obtain approval from QA FF NPM 50

and submit to customer

FF NPM 51
As per APQP FF FF NPM 52
In case of aerospace Prepare Part number accountability Process Engineering 
NPM 01 FF NPM 53
FF NPM 51, Product accountability FF NPM 52,
Characteristics accountability FF NPM 53 

As per APQP FF
3.14 Submit IMDS  Report in Portal Process Engineering 
NPM 01
3.2 Repeat steps 3.01  to 3.14 depending on the number of As per APQP FF
Process Engineering 
proto lots requested by customer NPM 01

3.3 Prepare and Identify the Known Good Board and FF NPM 54

As per APQP FF
Known Bad boards for the relevant stages  and update list Process Engineering 
NPM 01
of golden samples

FF NPM 27
3.4 Revisit the PFC FF NPM 27, PFMEA FF NPM 36 and As per APQP FF FF NPM 36
Process Engineering  FF NPM 37
Control Plan FF NPM 37 and make necessary updates NPM 01

3.5  Prepare PRE LAUNCH PFC, PFMEA and CONTROL As per APQP FF

Process Engineering 
PLAN along with CFT.  NPM 01

3.6 Amend all the process related Documents(if required) As per APQP FF

Process Engineering 
and release  NPM 01

4. PHASE IV - Work Order for Pilot

4.1.01 Issue Work order for Pilot build as per customer As per APQP FF FF WHM 06
Process Engineering 
requirement NPM 01

As per APQP FF FF WHM 07

4.1.02 Issue Materials as per Kit List Process Engineering 
NPM 01
4.1.03 Conduct line side review (LSR) for readiness to start As per APQP FF FF NPM 45
Process Engineering 
production using checklist FF NPM 45 NPM 01

4.1.04 Validate the tools / jigs / Fixtures and update the FF NPM 46

Quality Assurance - As per APQP FF
masterlist of tools / jigs / fixtures in case the validation is
KT-01 NPM 01
not  happened in the Proto work  order time

4.1.05 Carry out Stress and Strain measurement for the As per APQP FF FF NPM 46
Process Engineering 
requried process NPM 01

4.1.06 Conduct MSA studies for the required As per APQP FF FF NPM 46

Process Engineering 
gages/equipment. NPM 01

FF QAM 51

4.1.07 Conduct Process capability studies for the required Quality Assurance - As per APQP FF FF QAM 52
processes as defined in the process flow chart. KT-01 NPM 01

4.1.08 Verify process performance and confirm whether

process design targets are met and enter the actual data in Quality Assurance - As per APQP FF FF NPM 38
Process Benchmark Data & Quality Goals-Target Vs KT-01 NPM 01
Achieved FF NPM 38

As per APQP FF FF NPM 55

4.1.09 Carry out outgoing Layout Inspection as per Plan Process Engineering 
NPM 01
 As per APQP FF FF NPM 56
4.1.10 Prepare Test Coverage Matrix and % of coverage Process Engineering 
NPM 01

4.2 Repeat steps 1.01 to 1.10 depending upon number of Process As per APQP FF
Pilot lots requested by customer Engineering  NPM 01

As per APQP FF FF NPM 57

4.3 Packaging Evaluation:   Process Engineering 
NPM 01

4.4 Prepare PPAP file for automotive products and as FF NPM 58

requested by customer containing 19 elements of PPAP FF As per APQP FF FF NPM 54
Process Engineering 
NPM 58. one master sample at KT . Update golden sample NPM 01
list FF NPM 54

4.5 Intimate customer for PPAP batch production if As per APQP FF

PM
required  NPM 01

4.6 Work Order for PPAP batch

PM
FF WHM 06
As per APQP FF
4.6.1 Issue Work order for PPAP as per customer Quality Assurance -
NPM 01
requirement KT-01

As per APQP FF FF WHM 07

4.6.2 Issue Materials as per Kit List Process Engineering 
NPM 01
4.6.3 Freeze the Stage wise manpower and train the As per APQP FF
Process Engineering 
people on the product file and Customer requirements NPM 01

4.6.4 Conduct line side review (LSR) for readiness to start As per APQP FF FF NPM 45
Process Engineering 
production using checklist FF NPM 45. NPM 01

As per APQP FF
4.6.5 Carry out PPAP Production ( Customer PPAP) Process Engineering 
NPM 01

4.6.6 Pick 1 sample from PPAP batch and identify as a

FF NPM 54
Golden sample  (Ensure that picked sample is undergone As per APQP FF
Process Engineering 
for complete Layout Inspection) and update master list FF NPM 01

NPM 54

4.6.7 Prepare PSW FF NPM 56 and get the PSW signed off FF NPM 59
As per APQP FF
by NPD head/QA head  and Submit the PPAP document to Process Engineering 
NPM 01
customer

As per APQP FF FF OPM 04

4.6.8 Prepare TGR-TGW report FF OPM 04.  Process Engineering 
NPM 01

4.7 For automotive products wherever ISC (Initial supply FF NPM 61

As per APQP FF
control) is applicable, Initiate ISC Announcement FF NPM Process Engineering 
NPM 01
61
4.8 Prepare ISC Control plan FF NPM 38 for the Product FF NPM 38
As per APQP FF FF NPM 19
and Revise the inspection plan FF NPM 19 for custom built Process Engineering 
NPM 01
parts incorporating the strigent controls as per WI NPD XX

4.9 Announce ISC termination once the ISC Targets are FF NPM 61

As per APQP FF
met as per WI NPD XX and upon getting the confirmation Process Engineering 
NPM 01
from customer (SOP started at Customer end)

5.0 Receive feed back from customer and make corrective

and preventive actions. Ensure CAPA is reviewed and
As per APQP FF
closed.  Process Engineering 
NPM 01
Note : 8D, 5why or other problem solving techniques as
applicable.

As per APQP FF FF OPM 04

5.1 Prepare TGR & TGW Reports - (For Each Phase) Process Engineering 
NPM 01

5.2 Review/Revist FMEA and update all failure modes

As per APQP FF
which we have encountered during Development Period Process Engineering 
NPM 01
both internal failures and external failures

As per APQP FF
5.3 Prepare Production Control Plans Process Engineering 
NPM 01

5.4 Verify process performance and confirm whether FF NPM 49

As per APQP FF
process design targets are met and enter the actual data in Process Engineering 
NPM 01
Process Benchmark monitoring form FF NPM 49
 As per APQP FF FF NPM 62
5.5 Quality Planning Sign off Process Engineering 
NPM 01

5.6 All the problems faced during development analysis

shall be conducted and recorded in " In House complaint As per APQP FF
Process Engineering 
tracker (PDCA Sheet).
NPM 01
Review all phases and Close APQP file
 Process No:  QP/NPM/03
ISSUE No. 09
Process : Activity Planning Rev No: 00

APQP MATRIX

Category of Explanation Symbols Explanation

Product
X Prime Responsible
A Absolutely new product, no experience of producing that product.
XX Co- responsible
B Similar product that exist in organisation.
√ Applicable
XXX To be applicable
C  Any ECN (Engineering Change Notice) & PCN (Process Change Notice)
D Plant Location change 

Category of
Responsibility
the product
Applic
Phase APQP ELEMENTS Form Format A B C D BD Sales PM NPM SCM QAM HRM System EHS Remarks (If any)
ability

1.1)Review all Customer related commercial documents RFQ

,BFQ FF CRM 07customer ,PURCHASE ORDER, CONTRACT
√ √ √ √ √
REVIEW FF CRM 16. Manufacturing feasbility and Risk
analysis and JRQS and make consolidation of Requirements
1.2)Carry out customer Input Review Analysis and Inward the
List of Tools/Jigs/Fixtures/Samples given by Customer in the √ √
CIRA FF NPM 02
1.3)Generate Query list FF NPM 03 for all clarification with
√
customer

1.4)Carry out  the Risk analysis FF NPM 04 √

1.5)Study past development records and Record in FF NPM 05 √

2.1)Prepare Item Master FF NPM 06 by Verifying with

Datasheet for each Items, upload in ERP Run#: 3992, Upload √ √ √
Make & MPN in Run#: 3993
2.2) Generate the following parts list from ERP

1.List of LSL Items - FF NPM 07

2. List of specific consumables- FF NPM 08

3. List of Custom build items - FF NPM 09

4.. List of MSD items - FF NPM 10

√
5. List of Critical items - FF NPM 11

6. List of Items Requiring Re-finishing - FF NPM 12

7. List of Gold removal items - FF NPM 13

8. List of EOL parts - FF NPM 14

9. List of Parts having Marks of conformity FF NPM 15

2.3) Create BOM FF NPM 16 in .csv format and upload in ERP
run#: 3074
2.4) Conduct BOM Analysis For all Aerospace & Defence
products and record in FF NPM 17 as per WI NPM 02. Send
the BOM analysis to the Customer and take approval.
2.5) Conduct BOM Verification and approval
 

2.6) Do product wise process set up in Run# 2856 & Confirm

the BOM in Run#: 1298
2.7) Prepare Engineering Drawing FF NPM 18 in case
customer doesn't provide Drawing

Do Balooning for all Drawings

2.8) Create Incoming Quality Inspection Template for Custom
built Items in Run#: 2888

Specific Inspection plan FF NPM 19

2.9) Link all other items to Existing Incoming Quality Inspection
Template and Generate inspection BOM FF NPM 20

2.10) GERBER REVIEW

2.10.1) Do Gerber review FF NPM 21 in Run#: 3846

2.10.2)  Identify the supplier for PCB , discuss the Gerber with
the prospective supplier and get their inputs and Record in
Gerber review
2.10.3) Receive the panel Gerber from supplier if panalisation
is required

2.10.4) Review with Technical team and Finalise the Panel

Gerber

2.10.5) Link the gerber and specific drawings if any to the PCB

part Number

2.11) Prepare Preliminary Process Flow Design FF NPM 22

2.12) Prepare DFM Report

2.13) Prepare DFA Report

2.14) Prepare DFT Report

2.15) Prepare special product/process characteristics FF NPM

26 including appearance items.

2.16) Prepare Preliminary Process flow charts FF NPM 27 in

Run No.: 4875

2.17) Identify the programming requirements for applicable

manufacturing process and update in List of Program FF NPM
28
2.18) Prepare specific work instruction's, CADs and supporting
pin layout, Test Plan on FF NPM 29 wherever applicable

Note 1: Ensure CAD is made for SMD (DNP Locations), TH

Masking, TH Stuffing, Hand Soldering & Coating masking

Note 2: Ensure Supporting Pin Layout is made for Pick & Place
and Screen Printing stage if the PCBA is having both the sides
of components
2.19) Prepare Specific CTQ FF NPM 30 if any.

2.20) Prepare layout inspection plan FF QAM 31