PROCEDURE FOR DEVELOPMENT OF NEW

PARTS

1.0 Purpose :
To establish a procedure for new product or ECN product development and to ensure that the product development is carried out in line
with customer requirements and reduce the lead time of the development continually.
2.0 Scope :
This procedure is applicable for development of New product, Engineering change and any Process change, Supplier Change of
existing items or any similar component received or plant location change from RFQ to SOP at Customer End for Automotive Part
3.0 Responsibility

The overall responsibility of Implementation of this procedure is with NPD Head / Mng.

4.0 Activity Description :

The procedure has been made with the reference of APQP Manual AIAG 2nd Edition
The activity to be done with respect to scope of procedure and their respective responsible person are defined in APQP Matrix
(F:DEV:13)
APQP Timing Chart will be made based on category defined in APQP Matrix
The review of timing plan shall be done
1. CFT : Every 15 days,
2. Top Management along with CFT : Every month, End of Each Phase
Customer
During those review customer milestone shall also be discussed

S.No. ACTIVITY RESPONSIBILITY DOCUMENT NO..

Phase – 1 : Plan & Define

1 Receive customer enquiry / documents / sample / drawing. Marketing ---

2 Enter details in New Development List Of NPD Part/ECN Logbook. Development L:DEV:04

3 Review customer documents & resolve technical issue with customer. Development ---

Use best practices & take benefit of TGR / TGW and Past Defect History Development F:DEV:12 /
4
Records. F:DEV:21

5 Prepare BOM Development F:DEV:34

6 Supplier Selection Purchase F:PS:01

7 Define customer requirements, including special characteristics Development F:DEV:36

8 List of Equipment,Tooling, Instrument Required Development F:DEV:32A

9 Do Feasibility Study with CFT. Development F:DEV:32

10 Prepare Quotation, submit to customer & resolve commercial issues. Marketing ----

11 Follow up with customer if no response is received within a week. Marketing ---

Phase – 2 : Product Development

1 Receive Development Order from the customer/LOI Marketing ---

Prepare Product Development (APQP) Timing Plan to be prepared and

2 F:DEV:02
get approval of top management Development
3 Prepare Tool Development Plan. F:DEV:17
Development
4 Prepare Fixture Development Plan. F:DEV:17
Development
5 Prepare Instrument/Gauge and Testing Equipment Plan F:DEV:40
Development
S.No. ACTIVITY RESPONSIBILITY DOCUMENT NO..

Phase – 3 : Process Design & Development

PFD / Customer
1 Prepare Process Flow Chart.
Development Code/ Sr.no

2 CFT will Prepare PFMEA Matrix. F:DEV:39

Development
FMEA / Customer
3 CFT will Prepare PFMEA.
Development Code/ Sr.no
CP / Customer
4 Prepare Pre-launch Control Plan.
Development Code/ Sr.no
Prepare & display necessary Work Instructions & Inspection Standards
5 ----
for each production stage Development
6 Prepare Packing standard F:PD:67
Development
7 Procurement of Material ---
Purchase
8 Training to concerned person for trial run. F:HR:02
Development
9 T-1 Trial Run ---
Development
10 IPP Report F:PD:69
Development
11 Sample Submission ---
Development
12 Sample Approval from Customer Marketing ---

13 Follow up with customer if no response is received within a week. Marketing ---

14 T-2 Trial Run, If Required ---

Development
15 IPP Report F:PD:69
Development
16 Sample Submission ---
Development
17 Sample Approval from Customer Marketing ---

18 Follow up with customer if no response is received within a week. Marketing ---

19 T-3 Trial Run, If Required (….Tn) ---

Development
20 IPP Report F:PD:69
Development
21 Sample Submission ---
Development
22 Sample Approval from Customer Marketing ---

23 Follow up with customer if no response is received within a week. Marketing ---

24 Planning for SPC and MSA F:DEV:20

Development
Phase – 4 : Product & Process Validation

1 Training to concerned person for pilot Lot F:HR:02

Development
2 Start producing the Pilot Lot / Initial Parts. F:DEV:19 /F:PD:69
Development
Perform Measurement System Analysis & Process Capability Study as
3 F:QC:37 & 38
required. Quality
S.No. ACTIVITY RESPONSIBILITY DOCUMENT NO..

4 Conduct Product & Process Audit. F:QS:14 / C.P

Quality
Check pilot lot as per the Pre-launch Control Plan& prepare Layout
5 ---
Inspection Report and prepare all PPAP document, including PSW. Development
6 Evaluation of Packing Standard F:PD:67
Development
7 Submit pilot lot & PPAP documents to customer for approval. ---
Development
8 Follow up with customer if no response is received within a week. Marketing ---

Phase – 5 : Feedback Assessment & Corrective Action

Receive Pilot Lot Approval Documents from customer & hand over to Marketing
1 F:DEV:33
Quality
Record all quality issues in PDCA Analysis Sheet Faced In-house & at F:DEV:38 &
2
Customer End during Trials. Analysis to be done in CAPA sheet. Quality F:QS:55

3 Prepare TGR / TGW. F:DEV:12

Development
Prepare APQP Sign Off after SOP at Customer end for Mass Production
4 F:DEV:33
Sheet & hand over all documents to Production Development
Start Production under IPC & monitoring the production activities F:DEV:30 &
5
closely for each production lot. Quality F:DEV:31

PREPARED BY CHECKED BY APPROVED BY