Definition of APQP Activity "Start" and "Completed"

Completed (Condition) Parts MRD of

No. Item (English) Start (Condition) ★ Must be approved by company management Completion
★ If challenges arise after completing, re-open activity Timing

1 Phase Control

2 Mazda Input Requirements Supplier has received Mazda's general requirements (design Supplier has completed discussions with Mazda and there are FD
specification, QRS) and can begin internal discussions. no unclarities of Mazda requirements.

3 APQP Draw up CFT has started drawing up APQP. APQP start/planned completion dates are clearly defined and FD
supplier management has approved.

4 Concept Design Review Supplier has started Concept Design Review. Concept Design Review is completed, challenged to work on FD
are clear, and reaction plans are in place.

6 Design FMEA Supplier has started Design FMEA. Reaction policy, due date, and roles are defined for Design FD
FMEA results.

7 Past Concerns Recurrence Prevention (Design) Supplier has started extracting Past Concerns that require Necessary reaction plans for Past Concerns Recurrence FD
Recurrence Prevention. Prevention are defined.

8 Design Validation Test Design Validation (DV) Test has started. Test is completed and supplier has come to an agreement with DC
Mazda that DV Test is completed (retesting not required).

9 Risk Assessment for New/Changed (Design) Supplier has started risk assessment for New/Changed. Risk assessment for New/Changes is completed and a risk FD
mitigation plan has been determined.

11 Specific Design Review Specific Design Review has started. Specific Design Review has been completed and no challenged FD
remain. Or, challenges to be resolved are clear and reaction
plans are in place.

12 Agreement on required specifications Specifications of Materials is finalized. Specifications of Materials has been released upon consultation TTO
with Mazda and Mazda's approval has been obtained.

13 Sub-supplier APQP Status Control CFT has started drawing up sub-supplier's APQP. Sub-supplier's APQP start/planned completion date are clear. FD

20 Manufacturing Process Design & Concept Control Supplier has started reviewing manufacturing process design & Supplier has completed reviewing manufacturing process TTO
Plan concept control plan. design and concept control plan.

21 Process FMEA Supplier has started Process FMEA. Reaction policy, due date, and roles are defined for Process TTO
FMEA results.

22 Facility/Equipment　Preparation Sub-supplier or supplier has launched to build the mass Mass production line/facility are ready for use. TTO
production line/facility

31 Past Concerns Recurrence Prevention (Production) Significant Characteristics of Mazda requested specifications Supplier has completed extraction of Past Concerns that TTO
have been identified (agreed). require incorporation/validation.

32 Risk Assessment for New/Changed (Production) Supplier has started risk assessment for New/Changed in the Risk assessment for New/Changes is completed and a risk TTO
mass production process. mitigation plan has been determined.

34 Process Parameters Setting Review of process parameters (control items/control values) Process Parameters have been completely verified and Process TTO
has started. Parameters (control items/control values) are determined.

35 Preliminary Production Trial Run and Development Production Trial/production improvement activities have Production Trial/production improvement activities are PP
started. complete, there are no remaining challenges, and process is
finalized.

36 Measurement System Evaluation Measurement systems to be evaluated are determined and Verification has been completed. Review of accuracy TTO
verification has started. Supplier has started reviewing maintenance control plan has been completed.
accuracy maintenance control plan.

37 Control Plan Draw up of Control Plan has started. Initial versions of Control Plans have been completely drawn TTO
up.

38 Operator Work Instructions Draw up of Operator Work Instructions has started. Initial versions of Operator Work Instructions have been TTO
completely drawn up.

39 Operator Training Operator Training has started based on Control Plans and Operator's job proficiency has achieved the level pre- PP
Operator Work Instructions. determined by the supplier.

40 Packaging Specifications Development of Packaging Specifications has started to Mazda has agreed/approved the Mass Production Packaging TTO
establish Mass Production Packaging Specifications. Specifications.

41 Production Validation Test (Production) Production Validation Test has started using off-process test Mazda has agreed that PV Testing has completed (retests are PP
samples. not required).

47 Acceptance Samples Review for necessity of Acceptance Sample has started. Acceptance Samples for mass production quality have been PP
approved by Mazda.

52 Mass Production Trial Run Validation of Mass Production Trial Run can start. Mass Production Trial has been completely validated and no MP
remaining challenges remain.

54 Initial Mass Production Materials Inspection MP inspection materials are ready and MP ｍaterials have been completely inspected/measured and MP
inspection/measurements have started. inspection data can be submitted to Mazda.

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57 Materials Submission Declaration Necessary preparations are complete to submit Parts Parts Submission Declaration (for Materials) can be submitted MP
Submission Declaration (for Materials) to Mazda. to Mazda.

58 Initial Mass Production Intensive Control Initial Mass Production Intensive Control Plan has been drawn Initial Intensive Control can be safely closed. Within 6
up. months from
SOP

59 Lessons Learned Date when Lessons Learned started. Lessons Learned is complete and information to cascade to the Within 6
next vehicle model is determined. months from
SOP

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(QRS2012 Attachments "A-2 "APQP and Status Report ( for Materials)")
Advanced Product Quality Plan (APQP) and Status Report (for Materials)
Status Definition Supplier Name
R1 APQP Element not completed within the deadline requested by Mazda and there is no recovery p Issued Date
R0 APQP Element not completed within the deadline requested by Mazda, but there is a recovery plan. Revised Date
Y APQP Element is delayed, but a recovery plan is in place to complete activity by deadline reque Approved Reviewed PIC
G APQP Element will be completed without problems by deadline requested by Mazda.
C APQP Element is fully completed.

Project Product Name Today

20XX 20XX 20XX 20XX

Supplier Name Material Code

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

Supplier Code Mfg. Site ◆FD ◆DCV ◆TTO◆PP ◆MP

CFT Members

PIC Standard Planned Actual

deadline Planned Actual Start Supplier Implementation Plan
No. Phase APQP Element Scope (Person in Completion Completion Status Comments
requested by Start Date Date (Upper Column: PLAN / Lower Column: RESULT)
Charge) Date Date
QRS
Ex. APQP Phase Control ◆I ◆II ◆III ◆IV

Ex. Process FMEA CFT 8/31/2012 Y PFMEA needs to be revised

due to design change issued
end of Aug.

(1) Phase Control

(2) Mazda Input Requirements

I. Robust Product Design and Development

(3) APQP Draw up

(4) Concept Design Review

(6) Design FMEA

(7) Past Concerns Recurrence Prevention

(Design)

(8) Design Validation Test

(9) Risk Assessment for New/Changed

(Design)

(11) Specific Design Review

(12) Agreement on required specifications

(13) Sub-supplier APQP Status Control

(20) Manufacturing Process Design &

Concept Control Plan

(21) Process FMEA

(22) Facility/Equipment Preparation

II. Robust Production Process Readiness

(31) Past Concerns Recurrence Prevention

(Production)

(32) Risk Assessment for New/Changed

(Production)

(34) Process Parameters Setting

(35) Preliminary Production Trial Run and

Development

(36) Measurement System Evaluation

(37) Control Plan

(38) Operator Work Instructions

(39) Operator Training

(40) Packaging Specifications

(41) Production Validation Test

(Production)

(47) Acceptance Samples

III. Product and Production
Quality Verification

(52) Mass Production Trial Run

(54) Initial Mass Production Materials

Inspection

(57) Materials Submission Declaration

(58) Initial Mass Production Intensive

IV. Safe Launch

Control

(59) Lessons Learned

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Recovery Plan
(To be entered for APQP Elements with "Y" or "R" status)
Planned Planned
APQP Element Actual Actual
No. Concerns Reaction Plan PIC Completion Completion
(Status: "Y" or "R") Date Completion Date Date Completion Date

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(QRS2012 Attachments "A-2 "APQP and Status Report (for Materials)")
Advanced Product Quality Plan (APQP) and Status Report (for Materials)
Status Definition Supplier Name
R1 APQP Element not completed within the deadline requested by Mazda and there is no recovery plan. Issued Date
R0 APQP Element not completed within the deadline requested by Mazda, but there is a recovery plan. Revised Date
Y APQP Element is delayed, but a recovery plan is in place to complete activity by deadline requested by Mazda. Approved Reviewed PIC
G APQP Element will be completed without problems by deadline requested by Mazda.
C APQP Element is fully completed.

Project Product Name Today

Mazda Use Only. 20XX 20XX 20XX
Input if APQP activity is necessary or
not to perform. This area is to identify due date or
Supplier Name milestone for each APQP activity. Material
Input Code
Planned Input Actual Start Input Planned Input Actual Input the status for each activity complying with the
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
Y：Yes, the activity is needed. Completion Date, above Status Table. When the system is used, no
Blank : No, The activity is NOT needed. Basically, Mazda provides the format Start Date, Date, Please see Completion Date,
with this area being filled in as Mazda Please see the need to input this area because of the system
Supplier Code Please
Mfg. see
Sitethe the definitions in Please see the
definitions in automatic judgement being applied.
◆FD ◆DCV ◆TTO ◆PP ◆MP
asks suppliers to confirm the APQP definitions in different sheet. definitions in
different sheet. different sheet. different sheet.
activity schedule.
CFT Members

PIC Standard Planned Actual

deadline Planned Actual Start Supplier Implementation Plan
No. Phase APQP Element Scope (Person in Completion Completion Status Comments
requested by Start Date Date (Upper Column: PLAN / Lower Column: RESULT)
Charge) Date Date
QRS
Ex. APQP Phase Control ◆I ◆II ◆III ◆IV

Ex. Process FMEA PFMEA needs to be revised due

Y CFT FD(mm/dd/yyyy) 8/31/2020 8/30/2020 10/30/2020 Y to design change issued end of
Oct.

(1) Phase Control

(2) Mazda Input Requirements

I. Robust Product Design and Development

(3) APQP Draw up

(4) Concept Design Review

(6) Design FMEA

(7) Past Concerns Recurrence Prevention

(Design)

(8) Design Validation Test

(9) Risk Assessment for New/Changed

(Design)

(11) Specific Design Review

(12) Agreement on required specifications

(13) Sub-supplier APQP Status Control

(20) Manufacturing Process Design &

Concept Control Plan

(21) Process FMEA

(22) Facility/Equipment Preparation

II. Robust Production Process Readiness

(31) Past Concerns Recurrence Prevention

(Production)

(32) Risk Assessment for New/Changed

(Production)

(34) Process Parameters Setting

(35) Preliminary Production Trial Run and

Development

(36) Measurement System Evaluation

(37) Control Plan

(38) Operator Work Instructions

(39) Operator Training

(40) Packaging Specifications

(41) Production Validation Test

(Production)

(47) Acceptance Samples

III. Product and Production
Quality Verification

(52) Mass Production Trial Run

(54) Initial Mass Production Materials

Inspection

(57) Materials Shipping Declaration

(58) Initial Mass Production Intensive

IV. Safe Launch

Control

(59) Lessons Learned

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Recovery Plan
(To be entered for APQP Elements with "Y" or "R" status)
Planned Actual
APQP Element
No. Concerns Reaction Plan PIC Completion Completion
(Status: "Y" or "R") Date Date

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