PROCEDURE FOR ADVANCED PRODUCT

SP QUALITY PLANNING
SP/QSP/10

PROCEDURE FOR ADVANCED PRODUCT

QUALITY PLANNING
– SP/QSP/10

AMENDMENT SHEET

Issue No. & Rev. No. & Approved

# Description Page No. Issued By
Date Date By

00 & 00 &
01 Initial Release All Suresh Ramesh
11.04.2022 11.04.2022

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 PROCEDURE FOR ADVANCED PRODUCT
SP QUALITY PLANNING
SP/QSP/10

1.Guidelines
Start

Receipt of enquiry, Drawing, Specification from Customer

Form CFT

Review Drawing, Specification received from Customer

New Part Change in the existing part

No No
Prepare Team feasibility commitment

Inform customer if Not feasible Inform customer if Not feasible

Yes Yes
If feasible Prepare ECN Note & Inform
If feasible Inform customer customer

Decide the Product Development category & Prepare APQP matrix

Follow all the phases of APQP as called for in APQP matrix

Review the progress of the activity as per APQP matrix

If there is any delay observed, Record the Reason for the Delay & follow up
action

Is all the Phases of APQP has been completed & Results satisfactory

If Yes
If No Submit Pilot lot with documents for
Customer end SOP
If Yes
Obtain feedback from customer till customer SOP gets over
Result satisfactory?
If No

Prepare Quality plan Sign off & Follow Initial Production Control

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1. PURPOSE

This Procedure is to defining new product development and Changes in existing Parts
(ECN)/(PCN) and to define the process needed for the Product Quality planning process to
ensure that:
1. Resources are directed to satisfy the customer.
2. To promote early identification of problems / changes to avoid late changes
3. To provide a quality product on time at the lowest cost.
4. Use of CFT approach & Simultaneous engineering during design and development
process.
5. To Ensure flaw less launch.

2. SCOPE

Applicable to all new development parts and Changes in existing Parts (ECN Parts) and/or its
process (PCN).
From receipt of order to SOP at customer end.

3. RESPONSIBILITY

It is the responsibility of the Plant Head to ensure that this procedure is latest, implemented
and understood by all appropriate personnel across the organization.
It is the responsibility of the CFT & relevant functional heads to ensure that this procedure is
implemented in their respective departments.

1. PROCEDURE

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 PROCEDURE FOR ADVANCED PRODUCT
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Phase – I (Plan and Define the program / Pre contract review)

Sl. Responsibility/ Document No
Activity
No. Authority
Select NPD category based on nature of development from APQP
Activities matrix (SP/NPD-AM/01) & defining responsibility
accordingly.
AA - Absolutely new component: No Experience of Production
so far.
A - That the part happens to be similar to what had been APQP Activities
produced so far but there happens to be large-scale difference in
Matrix
raw material, Machining Methodology, In the structure or in the
function. Plant Head /
4.1.0 SP/NPD-AM/01
B - That Whenever there happens to be a Minor Deviation in the
CFT
Component produced so far(To implement only for inspection of
initial product) ECN & DCN Parts
C - That whenever there happens to be extremely minor change
in details related to the component, so much so that even the
inspection
becomes non mandatory(It becomes more of checks in regard to
monitoring of the points of variation in regard to 4M
D - That whenever there happens to be changed in production
site
Receive enquiry / Customer drawing / Customer provided
sample / any standards and specifications from CUSTOMER, By Email
4.1.1 Plant Head
Customer Milestone (T0,T1,T2, Sample submission time
requirement & SOP) (If any).
Perform enquiry review and the details will be entered in Enquiry
4.1.2 Register The details shall be reviewed for adequacy if engineering Plant Head SP/NPD-ENQ/01
drawing were provided by the customer.
Identify the Customer drawing, standards, if given by putting
`MASTER COPY’ on the rear side of the drawing and standard.
Mark the date of receipt suitably handwritten on the rear side Quality Engineer SP/MLD/01
4.1.3 and update the master list of customer drawing immediately. In
case if any drawings received for reference purpose as design
input, it can be considered only for reference by putting
`Reference only’ on the rear side of the drawing.
Photocopies of the customer drawing affixed with `CONTROLLED Quality Engineer --
4.1.4
COPY’ stamp can be used for reference purpose
Top management shall constitute a Manufacturing Cross SP/NPD-CFT/01
Functional Team consisting of members from Marketing, Plant Head
4.1.5
Production, Maintenance, Quality, and Purchasing to carry out
the Advanced Product Quality Planning. List of CFT Members
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 PROCEDURE FOR ADVANCED PRODUCT
SP QUALITY PLANNING
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Drawing Review: The drawing shall be reviewed by Plant Head. In SP/NPD-DRG/RE/

case of samples received from the customer, it can be used for 01
Comparative purpose only and does not absolve the CFT to CFT
comply with customer requirement as stated in the assembly
4.1.6 drawing.
Clarification from customer, If required:
During drawing review if any incomplete information is found,
Marketing
the marketing person shall interact with customer to get the
relevant required information.
---
Additionally CFT Team shall collect information on Internal voices
/ Past History based on:
a) In house rejections / Rework
b) Customer complaints
4.1.7 CFT SP/NPD-PH/01
c) Process changes and their impact
d) SPC results
e) TGR / TGW reports (Things Gone Wrong & Things Gone Right)

Pre – Feasibility Study: SP/NPD-PF/01

Conduct Pre-feasibility study to understand the manufacturer CFT
ability of new product within 15 days of drawing receipt.
For feasible products, a final Process details shall be prepared.
Engineering Change Note for the change in existing part is --
prepared. Engineering change Note shall be prepared within 10 CFT /
4.1.8
Working days & the same to be communicated to the customer.
Plant Head
The final Process details, and then is reviewed by MANAGER for
preparation of cost data sheet and facilitating submission of
Quotation.
If found not feasible, CFT shall send regret letter intimating the --
Plant Head
customer the inability to service this enquiry.
Reliability and Quality, Goals: (If required)
CFT Team shall identify goals in the form of: SP/NPD-QG/01
4.1.9 1.Product cycle time CFT
2.In-Process Rejection PPM
3. Process capability requirement
Bill of Materials: Plant Head /
4.1.10 CFT shall prepare a tentative material Parts List if required based --
Marketing
on Parts List, Purchase shall prepare an early subcontractor list.
Preliminary Process flow Chart:
4.1.11 Tentative process flow chart (Block diagram) shall be prepared by CFT SP/NPD-PFC/01
the CFT.

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Marketing shall provide a Quotation to the customer with lead-

time and validity of quote. Marketing shall resolve any difference
with the customer with regard to the quotation. Marketing to
monitor the status of the quote and shall be closed when
--
4.1.12 reasonable period of extension based on the interactions with MARKETING
the customer is over.
If at a later stage, the customer revises the same enquiry, it shall
be the prerogative / discretion of the Marketing / Top
Management to consider the enquiry at the earlier quote.
CFT Review: CFT Members will review the project status every
week & the same will be recorded in MOM. If any delay found, it Plant Head / SP/NPD-MRM/01
4.1.13 will be reviewed & corrective action planned. Timing plan also APQP
updated accordingly if required. This CFT review should be Champion
conducted for all the phases.
CFT Members shall appraise the Top Management about the
status and analysis for any variance to provide further SP/NPD-MRM/01
appropriate supports (Interims of Resource Requirements) and CFT / APQP
4.1.14
the same are minuted in Management support & Review Champion
Meeting Report. For Long duration project, the same shall be
reviewed month wise instead of phase wise.

Phase –II – (Product Design & Development, Team Feasibility Commitment)

4.2.1 Marketing shall accept a Purchase Order / LOI from the customer. Marketing By mail
4.2.2 CFT shall also conduct Contract Review If required. Plant Head --
The CFT shall be specific to the product and if required CFT --
4.2.3
representatives from other functions may be inducted
CFT develops New Product Development Plan (Master & Micro) as SP/NPD-MAP/
required by the organization, in-line with APQP Matrix (SP/ NPD - 01&
AM/01) based on category defined. SP/NPD-MIP/01
4.2.4 Master plan is prepared for overall monitoring process & Micro CFT
Plan: Process which involves more time are monitored through
Micro Level planning such as a tool / fixture development &
inspection testing establishment & process validation.
Identify customer defined special characteristics, Check for Quality / SP/NPD-SCM/01
4.2.5
Availability of published standards and record the details. Plant Head
Product error proofing, as appropriate: ----
4.2.6 CFT
CFT shall review for any Poka Yoke requirements to ensure the
error proofing / mistake proofing.
4.2.7 Engineering Drawings / Specifications / Material Specifications: CFT
CFT shall prepare process drawings and material specifications
based on Customer Drawing input if required. In addition to the ---
above, wherever applicable all engineering changes shall be as per
Process Manual for Document Control Process. Purchase shall

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SP QUALITY PLANNING
SP/QSP/10

insist through P.O. the traceability requirements like date and

month code to be followed wherever feasible on the Brought out.
New equipment/ Tooling / Gauges / Testing equipment / SP/NPD-TECL/01
4.2.8 Facilities requirements: & SP/NPD-CAL/01
CFT
Identify New Equipment, Toolings / Gauges / testing equipment
and Facilities Requirements to complete the project.
CFT shall review for other facilities, equipments and other --
CFT
resources that are required for the New product that is to be
4.2.9
developed.
Training for New process or operator that are required for new SP/NPD-TFC/01
HR
product will be provided.
Appropriate personnel of CFT shall prepare Proto Control Plan for
all processes as per the preliminary Process flow Chart. Control SP/QCPC
4.2.10 CFT
Plan shall be prepared based on APQP Manual / customer
approved methodology.
Evaluate feasibility through Product Data and Team Feasibility
Report. Marketing / Customer Representative shall interact with CFT / Plant SP/NPD/TFC-01
4.2.11 customer for any clarifications.
Head
Team feasibility Commitment Report shall be signed by the CFT
and the team now agrees to develop the new product.
CFT Review: CFT Members will review the project status every SP/NPD-MRM/02
Plant Head /
week & the same will be recorded in MOM. If any delay found, it
4.2.12 APQP
will be reviewed & corrective action planned. Timing plan also
Champion
updated accordingly if required.
CFT Members shall appraise the Top Management about the SP/NPD-MRM/02
status and analysis for any variance to provide further appropriate
supports (Interims of Resource Requirements) and the same are CFT / APQP
4.2.13
minuted in Management support & Review Meeting Report. For Champion
Long duration project, the same shall be reviewed month wise
instead of phase wise.

PHASE –III (Process Design & Development)

Appropriate personnel of CFT shall ensure that the following --
4.3.1 CFT
activities are carried out thru simultaneous Engineering method
CFT shall prepare Packaging standards / specifications that are --
required for the new product that is being developed
 Decide Packaging Specifications Quality /
4.3.2  Reflect Packaging Specifications in Work Instruction
CFT
 If Customer provides the packaging specification, the same shall
be used.(Materials are dispatch in customer allocated
bins/Crates/Trolleys/Carton Box).
4.3.3 CFT shall review the entire Quality System Documentation thru CFT SP/NPD-PQSR/01
Product / Process quality system review to ensure that the existing
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quality system is adequate to meet the requirements of new

product.
CFT shall prepare Process flow diagram as per the format to cover SP/PFD/01
4.3.4 CFT
the incoming source of variation and expected deliverables
Floor Plan Layout:
CFT shall prepare proposed floor plan layout in-line with PFC --
4.3.5 CFT
sequence. If the product is similar to the existing no need to
prepare floor plan layout.
CFT shall prepare Characteristics matrix (if required) for the new
product that is being developed. SP/NPD-SCM/01
4.3.6 CFT
 CFT to list all special Characteristic;
 Identify appropriate techniques for Process Control.
CFT shall conduct Process Failure Mode and Effect analysis SP/PFMEA/01
4.3.7 (PFMEA) for all value adding processes as per the PFMEA Manual / CFT
methodology given in Customer Supplier Development Manual.
Appropriate personnel of CFT shall prepare Pre-launch Control Plan SP/QCPC
for all processes as per the Process flow diagram. Control Plan shall
4.3.8 CFT
be prepared based on APQP Manual / customer approved
methodology.
Appropriate personnel of CFT shall prepare Process instructions
(Work Instructions) for all processes as the PFD.
 Develop Process Instructions based on the output of the above SP/WI/01
4.3.9 CFT
steps.
 Ensure Process Instruction referred in the Control Plan.
 Identify Special Characteristics Symbol in process Instructions.
Appropriate personnel of CFT shall prepare MSA plan as per the
requirement for which MSA to be conducted.
4.3.10 CFT
Develop MSA Plan indicating the process, type of MME, Product F/SPC/28
and Process Tolerance and the Appraiser and the time.
Appropriate personnel of CFT shall prepare Preliminary process
capability study plan
Prepare Plan indicating the process, Equipment and the qualified
4.3.11 appraiser and Tolerances; CFT
F/SPC/28
SPC Plan shall be for processes where there are special
characteristics as defined by the customer and / or as defined by
the CFT.
CFT Review: CFT Members will review the project status every SP/NPD-MRM/03
Plant Head /
week & the same will be recorded in MOM. If any delay found it
4.3.12 APQP
will be reviewed & corrective action planned. Timing plan also
champion
updated accordingly if required.
4.3.13 CFT Members shall appraise the Top Management about the status CFT / APQP SP/NPD-MRM/03
and analysis for any variance to provide further appropriate champion
supports (Interims of Resource Requirements) and the same are
minuted in Management support & Review Meeting Report. For

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Long duration, project shall be reviewed month wise instead of

phase wise.

PHASE – IV (Product and Process Validation)

CFT shall perform Job Verification setups. Produce samples for
initial product and process Establishment. Depending on the --
4.4.1 CFT
model, the actual quantity can be decided by the respective
CFT / based on customer requirement.
Production Trial Run :
 Produce samples as per pre-launch control plan for initial SP/NPD-TR/01 &
sample submission to the customer with PPAP SP/NPD-PDCA/01
Documentation for Customer requirements.
 Ensure significant production run quantity for PPAP run for
customers identified depending on the model the actual
quantity can be decided by the respective CFT / Customer.
 Follow up Results: Collect all issues found at
internal/customer end problem during trial run. CFT shall
4.4.2 conduct the analysis on the issues identified & take CFT
appropriate actions to solve the issue, same shall be
recorded in the PDCA .
 Whenever there is an issue in form, Fit and function during
trial, it should be analyzed & 8D to be prepared for the issue
reported.
 If any ECN identified at the time of production trial run pre-
ECN parts will be identified and stored with identification
tag- RED TAG and shall be moved/scraped based on
customer input.
4.4.3 During the Production Trial Run, CFT shall ensure that : CFT SP/MSA-R/01,
1. MSA study is conducted with follow-up action for SP/SPC, SP/NPD-
marginal/non capable system. PDCA/01 &
2. Preliminary Process capability study is conducted and
SP/PPAP
action plan is established where Cpk Values do not meet
customer / Default requirements.
3. Layout inspection: Conduct a lay out inspection in line with
the drawing shared by customer and prepare a report.
4. Production Part Approval Process (PPAP) as per customer
requirement Production Validation testing;
5. Process Validation: Conduct test that validate the products
made from production tools and processes meet
Engineering requirement ;
6. PFC Review (if required): Incase if required, review or
revise the process flow based on the need.
7. Packaging Evaluation is carried out.

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 Conduct trials and assess results,

 Carry out corrective actions,
 Freeze packaging standards and specifications.
8. Logistics: Marketing shall discuss with Customer on the
logistics front. Adopt the suitable & mutual agreed logistics
modem.
CFT shall prepare :
Production Control Plan
Production Process control standard SP/QCPC
Other documents as required (Statuary & regulatory, Health &
safety ,Environmental requirements)
4.4.4 CFT
Develop production Process control standard which is a logical
extension of pre-launch control plan and catering to all the
requirements of Production control plan
CFT shale ensure relevant Statuary & regulatory, Health &
safety, Environmental requirements are met if required.
CFT shall sign Quality planning sign off with production team to SP/NPD-QPS/01
assure that the new product developed has met the customer
4.4.5 CFT
requirements and that all tools, equipments, facilities, testing
requirements are in line with customer expectations
CFT Review: CFT Members will review the project status every SP/NPD-MRM/04
Plant Head /
week & the same will be recorded in MOM. If any delay found, it
APQP
will be reviewed & corrective action planned. Timing plan also
champion
updated accordingly if required.
CFT Members shall appraise the Top Management about the SP/NPD-MRM/04
status and analysis for any variance to provide further
appropriate supports (Interims of Resource Requirements) and CFT / APQP
4.4.6
the same are minuted in Management support & Review champion
Meeting Report. For Long duration project, the same shall be
reviewed month wise instead of phase wise.

PHASE V (Feedback Assessment and Corrective Action)

4.5.1 Track customer feedback after pilot lot SOP at customer end and --
IPC submission and its Corrective action. The overall objective of
this process shall be:
Reduced variation CFT
 Incorporate ongoing process performance meeting
Cpk>1.67 for all special characteristics.
 Identify CI projects to reduce variations
SOP at Customer end: CFT --
Get the start of production plan at customer end and work towards
to achieve the same. this has to be monitored through timing plan
Customer satisfaction

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Evaluate customer Satisfaction

Delivery
Monitor 100 % delivery performance.
CFT shall prepare Things Gone Right (TGR) and Things Gone SP/NPD-PDCA/01
4.5.2 Wrong (TGW) TGR/TGW Report and also define corrective CFT
actions that are required.
CFT Review: CFT Members will review the project status every SP/NPD-MRM/05
Plant Head /
week & the same will be recorded in MOM. If any delay found, it
4.5.3 APQP
will be reviewed & corrective action planned. Timing plan also
champion
updated accordingly if required.
CFT Members shall appraise the Top Management about the SP/NPD-MRM/05
status and analysis for any variance to provide further
appropriate supports (Interims of Resource Requirements) and CFT / APQP
4.5.4
the same are minuted in Management support & Review champion
Meeting Report. For Long duration project, the same shall be
reviewed month wise instead of phase wise.
Start of initial production control Plant Head & QSP / 12
4.5.5
Quality Head

CROSS REFERENCES:
Document Reference
Sl. No. Description Reference
1 Procedure for Marketing --

2 Procedure for Breakdown & Preventive Maintenance QSP/15

Record Reference
Sl. No. Description Reference
1 APQP Activities Matrix SP/NPD-AM/01
2 List of CFT Members SP/NPD-CFT/01
3 Enquiry Register SP/NPD-ENQ/01
4 Experience Sharing SP/NPD-ES/01
5 Team Feasibility Commitment SP/NPD-TFC/01
6 New Product Development Master Plan SP/NPD-MAP/01
7 New Product Development Micro Plan SP/NPD-MIP/01
8 Management Of Review Meeting SP/NPD-MRM
9 Cost Estimation ----
10 Quotation ------
11 Purchase Order -----
12 Contract Review -----
13 List of new equipment’s / Tooling / Gauges / Facilities SP/NPD-TECL/01

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14 Risk Analysis SP/NPD-RA/01

15 Team Feasibility Commitment SP/NPD-TFC/01
16 Packaging standards / specifications ---
17 Product / Process quality system review SP/NPD-PQS/01
18 Process flow diagram SP/PFD/01
19 List of Special Characteristics Matrix SP/NPD-SCM/01
20 Potential Process FMEA SP/PFMEA
21 Target For Productivity, Process Capability & Cost SP/NPD-QG/01
22 Proto type Control Plan SP/QCPC/01
23 Manufacturing Feasibility Review Report SP/NPD-MFR/01
24 Product/Process Quality System Review Checklist SP/NPD-PQS/01
25 Control Plan- Prelaunch SP/QCPC
26 Process instructions (Work Instructions) SP/WI-SOP
27 MSA Reports SP/MSA
28 SPC Reports SP/SPC
29 PPAP Reports SP/PPAP
30 Control Plan- Production SP/QCPC
31 Checking Aids List SP/NPD/CA/01
32 Quality Planning Sign Off SP/NPD-QPS/01
33 PDCA( Trial Report) SP/NPD-PDCA/01

• - Customer Representative shall maintain copies of the above records in the APQP file for
each part.

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