APQP Checklist Report.version 1.1.Dtd. 13.11.08

MR0 MR2 MR3

Go / No-Go Design Freeze

Run@Rate Final

Report

Phase 1.0 Plan and Define Project

Phase 2.0 Product Design and Development

Phase 3.0 Process Design and Development

Phase 4.0 Product and Process Validation

Handover Period SoP +/- 90 days

Phase 5.0 Feedback, Assessment and Corrective Actions

Project Controlling and other supporting PDS processes

MR5

Model and Drawing Design Review

Manufacturing Facility Design

Approval

ToolingDesignFreeze

PS0 MR4 PS4PS2 PS3

Concept Prototype Pilot SoP

Management Review Phase Sign-Off

Project Approval

Phase 0.0 Project Initiation

APQP Product Development System (PDS) - Project :Project Management position

PS1MR1

Management Review Phase Sign-Off

Final Report

Handover Period SoP +/- 90 days


Project Controlling and other supporting PDS processes

MR5

Production Support

Production Controlling

PS5

document.xls.XLS APQPSTAT (UK Version) 5/50 Rev. Date: 7/21/06

Advanced Product Quality Planning ( APQP) Checklist

Start Date:Plant Name: Date:

Plant Location: Part Number:Plant Code: Part Name:

Specification / Drawings No:New: Site Technology Process Version:

Other Risks Plant:

Team Members Company / Responsibility Tel/Mobile No E-mail

Mr. Robbie Howarth APQP Project AdviserPlant Project Team Leader

Chief Engineer (R & D)Project Team Member (Maintenance)Project Team Member (Purchasing)

Project Team Member (Finance)Project Team Member (Sales)

Project Team Member (Production Operator)Project Team Member (Quality)

Project Team Member (Production Supervisor/Team Leader)

Material Required Date Quantity Special Characteristics Comments

APQP Elements G Internal

Completion Date Champion Name

Document

Comments / Action PlanY Completion Revision

R Date Date & Rev.

Phase 0.0 Project Initiation 0.1 Request for Quotation (RFQ) Registration0.2 Quotation Kick-Off and Team Setup0.3 Formulation of Quote0.4 FEP plus & Customer Specific Quote0.5 Handover Quote0.6 Phase 0 Gate Review & Sign Off Ops Team

Phase 1.0 Plan and Define Project1.1 Project Kick-Off and Set Up Project Folder1.2 Define Financial Baseline1.3 Refine Preliminary Design Chacteristics1.4 Refine Preliminary Process Flow and Manufacturing Facilities1.5 Preliminary Tooling and Manufacturing Facilities Plan1.6 Corrective Actions1.7 Phase 1 Gate Review & Sign Off Ops Team

Phase 2.0 Product Design & Development2.1 DFMEA2.2 DFMA2.3 Preliminary PFMEA2.4 Design Verification Plan & Report2.5 CAD Model & Simulations2.6 "Make or Buy" Evaluation - Design Review (Model and Drawing)2.7 Assessment and Selection of Suppliers2.8 Prototype Control Plan2.9 Production Process Flow Chart2.10 Prototype Construction and Review2.11 Engineering Drawings - Design Review (Design Freeze)2.12 Datebase2.13 Corrective Actions2.18 Phase 2 Gate Review & Sign Off Ops Team

Phase 3.0 Process Design and Development3.1 PFMEA3.2 Manufacturing Facility Design3.3 Pre-Launch Control Plan3.4 Measurement Systems Analysis Plan3.5 Production Equipment Safety3.6 Process Instructions and Training Plan3.7 Manufacturing Facility Design Approval3.8 Tool Design and Tool FMEA3.9 Verification of Tool Bill of Parts3.10 Verification of Part Dimensions3.11 Verification of Tool Functionality3.12 Tool Design Review3.13 Packaging Specification3.14 Corrective Actions3.15 Phase 3 Gate Review & Sign Off Ops Team

Phase 4.0 Product and Process Validation4.1 Gauge R & R4.2 Gauge Certification and Registration4.3 Training Builds4.4 Tool Tryout4.5 Tool Life Deviation4.6 Production Approval for Tool & Manufacturing Facilities4.7 DVP & R Concluded4.8 Production Control Plan4.9 Production Part Approval Process (PPAP)4.10 Internal [email protected] Production System Audit4.12 Run @ Rate4.13 Corrective Actions4.14 Phase 4 Gate Review & Sign Off Ops Team

Phase 5.0 Feedback, Assessment and Corrective Actions5.1 Handover of Project Responsibility to Production5.2 Management Review and Phase 5 Sign-Off5.3 Launch Support (CIP)5.4 Phase 5 Gate Review & Sign Off Ops Team

Overall Project Phases Review & Sign Off UM/FWW

- COMMENTS

Required Form

Risk Assessment Status: High Medium Low

Build LevelPrototype

Project Due Date

B18

APQP Team Participants; Supplier, Sub-tier suppliers, and BorgWarner Personnel, including all affected Plants.

P30

Define the Number of Special Characteristics; that may be customer specific; including: "Significant" "Major" "Critical" "High Impact" that requires on-going statistical capability and / or requires validation in the Process Control Plan .

L40

Status = Green, Yellow or Red as defined in definitions tab Numbers in this column correspond to the AIAG APQP manual definitions (ie. 1.7 refers to Design Goals)

R40

The current revision & date for the applicable document

S40

Contingency plans are required for any element that has a yellow or red status.

B50

Timing Plan must include all production process and BW program milestones

B58


B73


B89


B104


Issued By: Issued Date: Issue No.:

Page 1 of 10 Latest Date : 04/09/2023

Report No.

Date:

Quality StatusSystem Unsatisfactory Satisfactory Other Previous Rating and % Percentage Conformance

Attendees (Supplier) Department Attendees (LT) Department

2010 2011J F M A M J J A S O N D J F M A M J J A S O N D

Su

n C

lau

se

Sta

tus

Next APQP Date

Prototype

Programme Key Dates Functional

Job 1 Action Required


Ph

as

e 0

.0

0.1 Request for Quotation (RFQ) Registration 0.1

0.2 Quotation Kick-Off and Team Setup 0.2

0.3 Formulation of Quote 0.3

0.4 FEP plus & Customer Specific Quote 0.4

0.5 Handover Quote 0.5

0.6 Phase 0 Gate Review & Sign Off

Phase 1.0 Plan & Define Project

Ph

as

e 1

.0 P

lan

& D

efi

ne

Pro

jec

t 1.1 Project Kick-Off and Set Up Project Folder 1.1

1.2 Defrine Financial Baseline 1.2

1.3 Refine Preliminary Design Chacteristics 1.3 O1.4 Refine Preliminary Process Flow and Manufacturing Facilities 1.4

1.5 Preliminary Tooling and Manufacturing Facilities Plan 1.5

1.6 Corrective Actions 1.6

1.7 Phase 1 Gate Review & Sign Off 1.7

Phase 2.0 Product Design & Development

Ph

as

e 2

.0 P

rod

uc

t D

es

ign

& D

ev

elo

pm

en

t

2.1 DFMEA 2.1

2.2 DFMA 2.2

2.3 Preliminary PFMEA 2.3

2.4 DVP & R 2.4

2.5 CAD Model & Simulations 2.5

2.6 "Make or Buy" Evaluation - Design Review (Model and Drawing) 2.6

2.7 Assessment and Selection of Suppliers 2.7

2.8 Prototype Control Plan 2.8

2.9 Production Process Flow Chart 2.9

2.10 Pfrototype Construction and Review 2.1

2.11 Engineering Drawings - Design Review (Design Freeze) 2.11

2.12 Datebase 2.12



Phase 3.0 Process Design & Development

Ph

as

e 3

.0 P

roc

es

s D

es

ign

& D

ev

elo

pm

en

t

3.1 PFMEA 3.1

3.2 Manufacturing Facility Design 3.2

3.3 Pre-Launch Control Plan 3.3

3.4 Measurement Systems Analysis Plan 3.4

3.5 Production Equipment Safety 3.5

3.6 Process Instructions and Training Plan 3.6

3.7 Manufacturing Facility Design Approval 3.7

3.8 Tool Design and Tool FMEA 3.8

3.9 Verification of Tool Bill of Parts 3.9

3.10 Verification of Part Dimensions 3.10

3.11 Verification of Tool Functionality 3.11

Tool Design Review 3.11

3.12 Packaging Specification 3.12



Phase 4.0 Product & Process Validation

Ph

as

e 4

.0 P

rod

uc

t &

Pro

ce

ss

Va

lid

ati

on

4.1 Gauge R & R 4.1 C4.2 Gauge Certification and Registration 4.2

4.3 Training Builds 4.3

4.4 Tool Tryout 4.4 O4.5 Tool Life Deviation 4.5

4.6 Production Approval for Tool & Manufacturing Facilities 4.6

4.7 DVP & R Concluded 4.7

4.8 Production Control Plan 4.8

4.9 Production Part Approval Process (PPAP) 4.9 B4.10 Internal Run@Rate 4.1

4.11 Production System Audit 4.11

4.12 Run @ Rate 4.12




Ph

as

e 5

.0

5.1 Handover of Project Responsibility to Production 5.1

5.2 Management Review and Phase 5 Sign-Off 5.2

5.3 Launch Support (CIP) 5.3


Overall Project Phases Review & Sign Off

C CompletedO On Schedule

Advanced Product Quality Planning

Status Report



B Behind schedule with no catch up plan



Report No.

Date:

Quality StatusPercentage Conformance

Department

Next APQP Date

Action Required

document.xls.XLS APQPSTAT (German Version) 9/50 Rev. Date: 7/21/06


Ausgabedatum: Formularnummer: Anlage zu EW 017

Hersteller: Neumayer Tekfor Datum 10/27/2008

Ort: Hausach Überarbeitungsnummer: #

Projekt / Teilenummer: 6953.49.00

Spezifikation / Zeichnungsnr.:Neu: Ort Technologie x Prozess x Änderungsstand: 3

Risiko Werk: Hausach

Team Mitglieder Firma / Tätigkeit Fax e-mail

Hr. Dr.Koerner Projektleiter [email protected]. Roser Projektmanagement [email protected]

Hr. Schmid Industrialisierung [email protected]

Required Date Quantity Special Characteristics Comments

APQP Elements G Projekt Internes erledigt Champion Document Bemerkungen / Aktionsplan

Y Fälligkeits- Soll Name Revision

R Datum Datum Datum Date & Rev.

Phase 0.0 Project Initiation 0.1 RFQ (Request for Quotation) Registration0.2 Quotation Kick-Off and Team Setup0.3 Formulation of Quote0.4 FEP plus & Customer Specific Quote0.5 Handover Quote0.6 Phase 0 Gate Review & Sign Off Ops Team

Phase 1.0 Plan and Define Project1.1 Project Kick-Off and Set Up Project Folder1.2 Defrine Financial Baseline1.3 Refine Preliminary Design Chacteristics1.4 Refine Preliminary Process Flow and Manufacturing Facilities1.5 Preliminary Tooling and Manufacturing Facilities Plan1.6 Corrective Actions1.7 Phase 1 Gate Review & Sign Off Ops Team

Phase 2.0 Plan and Define Project2.1 DFMEA2.2 DFMA2.3 Preliminary PFMEA2.4 DVP & R2.5 CAD Model & Simulations2.6 "Make or Buy" Evaluation - Design Review (Model and Drawing)2.7 Assessment and Selection of Suppliers2.8 Prototype Control Plan2.9 Production Process Flow Chart2.10 Pfrototype Construction and Review2.11 Engineering Drawings - Design Review (Design Freeze)2.12 Datebase2.13 Corrective Actions2.18 Phase 2 Gate Review & Sign Off Ops Team

Phase 3.0 Process Design and Development3.1 PFMEA3.2 Manufacturing Facility Design3.3 Pre-Launch Control Plan3.4 Measurement Systems Analysis Plan3.5 Production Equipment Safety3.6 Process Instructions and Traininbg Plan3.6 Manufacturing Facility Design Approval3.7 Tool Design and Tool FMEA3.8 Verification of Tool Bill of Parts3.9 Verification of Part Dimensions3.10 Verification of Tool Functionality Tool Design Review3.11 Packaging Specification3.12 Corrective Actions3.13 Phase 3 Gate Review & Sign Off Ops Team

Phase 4.0 Product and Process Validation4.1 Gauge R & R4.2 gauge certification and Registration4.3 Training Builds4.4 Tool Tryout4.5 Tool Life Deviation4.6 Production Apporval for Tool & Manufacturing Facilities4.7 DVP & R Concluded4.8 Production Control Plan4.9 PPAP4.10 Internal [email protected] Production System Audit4.12 Run @Rate4.13 Corrective Actions4.14 Phase 4 Gate Review & Sign Off Ops Team



- COMMENTS

Required Form


B18


P30


L40


R40


S40


B50


B58


B73


B89


B104


document.xls.XLS APQPSTAT (Italian Version) 10/50 Rev. Date: 7/21/06






















- COMMENTS

Required Form


B18


P30


L40


R40


S40


B50


B58


B73


B89


B104


document.xls.XLS APQPSTAT (Brazil) 11/50 Rev. Date: 7/21/06






















- COMMENTS

Required Form


B18


P30


L40


R40


S40


B50


B58


B73


B89


B104



Ph

ases

Responsibilities

Department Cus

tom

er

AP

QP

Adv

isor

/Fac

ilita

tor

Person Rob

bie

How

arth


Phase 0

0.1 Request for Quotation (RFQ) Registration R C

0.2 Quotation Kick-Off and Team Setup C

0.3 Formulation of Quote C

0.4 FEP plus & Customer Specific Quote C

0.5 Handover Quote C

0.6 Phase 0 Gate Review & Sign Off R R C

Phase 1.0 Plan & Define Project

Phase 1

1.1 Project Kick-Off and Set Up Project Folder I I I I I C R C

1.2 Defrine Financial Baseline C

1.3 Refine Preliminary Design Chacteristics I C

1.4 Refine Preliminary Process Flow and Manufacturing Facilities C

1.5 Preliminary Tooling and Manufacturing Facilities Plan C

1.6 Corrective Actions C

1.7 Phase 1 Gate Review & Sign Off R C

Phase 2.0 Product Design & Development

Phase 2

2.1 DFMEA R I C

2.2 DFMA R C A C

2.3 Preliminary PFMEA C R C

2.4 DVP & R R C

2.5 CAD Model & Simulations C

2.6 "Make or Buy" Evaluation - Design Review (Model and Drawing) R R C

2.7 Assessment and Selection of Suppliers C

2.8 Prototype Control Plan C

2.9 Production Process Flow Chart R C

2.10 Pfrototype Construction and Review R C

2.11 Engineering Drawings - Design Review (Design Freeze) C

2.12 Datebase R C


2.18 Phase 2 Gate Review & Sign Off R R C

Phase 3.0 Process Design & Development

Phase 3

3.1 PFMEA C

3.2 Manufacturing Facility Design C

3.3 Pre-Launch Control Plan C

3.4 Measurement Systems Analysis Plan C

3.5 Production Equipment Safety C

3.6 Process Instructions and Training Plan R C

3.6 Manufacturing Facility Design Approval C

3.7 Tool Design and Tool FMEA C

3.8 Verification of Tool Bill of Parts R C

3.9 Verification of Part Dimensions A C

3.10 Verification of Tool Functionality C

Tool Design Review C

3.11 Packaging Specification C



Phase 4.0 Product & Process Validation

Phase 4

4.1 Gauge R & R C

4.2 Gauge Certification and Registration C

4.3 Training Builds C

4.4 Tool Tryout C

4.5 Tool Life Deviation C

4.6 Production Approval for Tool & Manufacturing Facilities C

4.7 DVP & R Concluded C

4.8 Production Control Plan C

4.9 Production Part Approval Process (PPAP) C

4.10 Internal Run@Rate C

4.11 Production System Audit R C

4.12 Run @ Rate C


4.14 Phase 4 Gate Review & Sign Off R


Phase 5

5.1 Handover of Project Responsibility to Production C

5.2 Management Review and Phase 5 Sign-Off C

5.3 Launch Support (CIP) C


Overall Project Phases Review & Sign Off R

Responsible RAccountable A

Consulted CInformed I

APQP PROJECT DEVELOPMENT SYSTEM

APQP Document Change List

No: Date Doc # Change Reason for Change1

APQP Document Change List

Title Page #

APQP Project Timetable

document.xls.XLS Open Issues 16/50 Rev. Date: 7/21/06

Open Issues - Action Plans

Date Description of Concern Actions Taken / Implemented StatusAPQP

Phase & Element

Name of Responsibility

Completion Date

document.xls.XLS Meeting Log 17/50 Rev. Date: 7/21/06

Meeting Log

Date of APQP Meetings

Name of Participant Kick-off 1 2 3 4 5 6 7 8 9

Optional Form

Team Feasibility CommitmentFeasibility Considerations

Plant Customer / Product Date Revision level: Customer: Date:

Part Name: Part No:

Requirements Comments/Actions Required Task Status Due Date

1

Task Not Complete

2

Can Engineering Performance Specifications can be met as written?

Task Not Complete

3

Task Not Complete

4

Is there adequate capacity to produce product?

Task Not Complete

5 Task Not Complete

6

Task Not Complete

7

Task Not Complete

8 Task Not Complete

9

Task Not Complete

10 Task Not Complete

ConclusionTOTAL PERCENTAGE COMPLETE

0%

Feasible 0 Product can be produced as specified with no revisions TOTAL PERCENTAGE INCOMPLETE111%

Feasible 0 Changes recommended or open issues need addressed (see attached)

Not Feasible 0 Design revision required to produce product with the specified requirements

Approval

Team Leader/Date: Quality Engineer / Date:

Tooling Engineer/Date: Manufacturing Engineer / Date:

Industrial Engineer/Date: General Manager / Date:

Material Manager / Purchasing / Date: Account Manager / Date:

Production Supervisor / Date: APQP Engineer / Date:

Title: Title:

Our product quality planning team has considered the following questions. The drawings and/or specifications provided have been used as a basis for analyzing the ability to meet all requirements. All "no" answers are supported with attached comments identifying our concerns and/or proposed changes to enable the organisation to meet specified requirements.

Resp. Initials

Is product adequately defined (application requirements, etc.) to enable feasibility evaluation?

Can product can be manufactured to tolerances as specified on drawing and in accordance with the DBL and Lastenheft?

Product can be manufactured with Cpk's that meet minimum 1.33 requirements (1.67 on safety related items).

Product can be manufactured with Cpk's that meet minimum 1.33 requirements (1.67 on safety related items).

Where statistical process controls is(are) used on similar products, the processes are stable and in control.

Where statistical process controls is(are) used on similar products, Cpk's are greater than 1.33 (1.67 on safety related items).

Lessons learned from similar products have been reviewed by the team. How? When?

The Suppliers APQP Team has reviewed and signed off the Feasiblity Commitment Checklist.

F7

SVS: Supplier to note any commnets or actions required to complete task

L7

SVS: Supplier pick form list answer to show current status

M7

SVS: Suppler to assign responsibilty to tasks

N7

SVS: Supplier to assign due dates for completion. All dates to be before the due date for each check list.

DFMEA

Please place a copy of the DFMEA in this tab

Commercial Checklist

Plant Customer / Product Date


1 The Letter of Intent has been signed by NTG and the supplier.

Task Not Complete

2 The Tooling P. O. has been received.

Task Not Complete

3 The Manufacturing Location has been chosen.

Task Not Complete

4 Annual Volume has been determined.

Task Not Complete

5 A project timeline has been developed & submitted to the customer.

Task Not Complete

6

Task Not Complete

7

Task Not Complete

8

Task Not Complete

9 The latest Engineering change is quoted and submitted to Purchasing.

Task Not Complete

10

Task Not Complete

11

Task Not Complete

12

Task Not Complete

TOTAL PERCENTAGE COMPLETE0%

TOTAL PERCENTAGE INCOMPLETE100%

Resp. Initials

All PPAP requirements are documented and understood to allow for Customer payment of tooling and/or equipment.

Sufficient money is budgeted for the purchase of gages, or other required verification equipment (measurement systems & testing equipment).

There are no additional costs required beyond the quotation that need to be discussed with the customer.

The latest Engineering change is to all agreed ESI (Early Supplier Involvement) specifications (I.e. test, material, datum schemes, tolerances, etc.)

All changes to date have been agreed to by Schefenacker Engineering and Purchasing.

The customers Supplier Quality Manual and its related expectations/measurements have been completely reviewed, understood and agreed to.

Design Information Checklist



1

Task Not Complete

2

Task Not Complete

3

Task Not Complete

4 Drawing tolerances are compatible with accepted manufacturing standards.

Task Not Complete

5 All requirements specified can be evaluated using known inspection techniques.

Task Not Complete

6

Task Not Complete

7 The intended material suppliers are on the customer approved list.

Task Not Complete

8 Material suppliers will be required to provide certification with each shipment.

Task Not Complete

9 Material characteristics requiring inspection have been identified.

Task Not Complete

10 Critical material characteristics can be checked by the supplier.

Task Not Complete

11 All outside testing laboratories used will be accredited.

Task Not Complete

12 Material handling impact on the design has been considered.

Task Not Complete

13 Material storage impact on the design has been considered.

Task Not Complete

14 Environmental concerns with the materials or process have been considered.

Task Not Complete

15 The bill of material is complete.

Task Not Complete

16 The DFMEA is available for review.

Task Not Complete

17

Task Not Complete

18

Task Not Complete

19 The product test plan is complete and approved by SVS NPI team.

Task Not Complete

20 The supplier has copies of the performance and material specifications

Task Not Complete



Resp. Initials

Dimensions or properties that affect fit, function and durability have been identified.

Key Quality Characteristics (KQC) and Key Process Characteristics (KPC) have been selected and documented. All known customer concerns have been identified to facilitate the selection of KQC's and KPC's.

Sufficient control points and datum surfaces are identified to design functional gages.

Specified materials are compatible with the durability requirements in the identified environment.

Specified raw materials (example: steel) are commercially available in country of manufacture.

All pending Engineering changes that may postpone the start of tooling, fixturing, raw material purchases, etc… have been accounted for and implemented into the timing with no detrimental timing changes.

Key Quality Characteristics

Please list the Key Quality Characterstics and methods to be used to monitor in this area

Tooling Checklist



1 Tool sources have been identified.

Task Not Complete

2 The tool design has provided for quick change if necessary.

Task Not Complete

3 The tool design has provided for volume fluctuations, where applicable.

Task Not Complete

4 Mistake proofing needs were incorporated in the tool design.

Task Not Complete

5

Task Not Complete

6 Process safety was considered in the design of the tooling.

Task Not Complete

7

Task Not Complete

8 The Tooling Design has been completed.

Task Not Complete

9 The supplier has approved the tool design.

Task Not Complete

10 The Tooling has been kicked off.

Task Not Complete

11 A timeline with sufficient tooling detail has been submitted to the customer.

Task Not Complete

12 Tool Tracking Sheets have lists prepared identifying all new tooling.

Task Not Complete

13

Task Not Complete

14

Task Not Complete

15 There is a preventive maintenance plan for tooling.

Task Not Complete

16 A spare parts list has been developed.

Task Not Complete

17 Setup instructions for new tooling are complete and understandable.

Task Not Complete

18

Task Not Complete

19

Task Not Complete

20 Allowable limits for burrs, flash, and trimming are documented and understood.

Task Not Complete

21 Standards for Class-A , B, C, and D surfaces are documented and understood.

Task Not Complete

22 Certified checking fixtures will be available at the tool source for part run-offs.

Task Not Complete

23 Parting lines and gate locations are documented and understood (molded parts).

Task Not Complete



Should we distinguish between our tools we give suppliers and tools they make? Or add statement for tools they make?

Resp. Initials

Key quality characteristics and key process characteristics were considered in the design of the tooling.

The material specifications, including physical and chemical properties of the material to be processed in the tool, were considered in the design of the tooling.

The supplier and tooling contractor have a written acceptance criteria for new tooling.

Preliminary capability studies or a sample run-off will be conducted at the tooling manufacturer.

Parts submitted from tools to Painter and SVS for evaluation and buy-off (painted product).

Tooling Preventive Maintenance established and approved by SVS and Painter (painted product).

Process Flow Chart Checklist



1

Task Not Complete

2 The DFMEA was used to develop the process flow chart.

Task Not Complete

3

Task Not Complete

4

Task Not Complete


TOTAL PERCENTAGE OPEN100%

Resp. Initials

The process flow chart illustrates the production sequence, production methods and inspection stations including all incoming components.

The operation number on the flowchart will be carried over to the control plan and the Process FMEA.

Provisions have been made to identify and inspect reworked products before being used. The rework and requalification loop is illustrated on the flowchart.

Process FMEA Checklist



1 If applicable, the DFMEA was used to help develop the PFMEA.

Task Not Complete

2

Task Not Complete

3 The PFMEA was developed using the Process Flow Chart.

Task Not Complete

4

Task Not Complete

5 Experience with similar parts and lessons learned were considered for the PFMEA.

Task Not Complete

6 Historical plant returns, campaign and warranty data were considered for the PFMEA.

Task Not Complete

7

Task Not Complete

8 Appropriate corrective actions have been planned or taken for high severity numbers.

Task Not Complete

9

Task Not Complete

10

Task Not Complete

11 Risk priority numbers were revised when a corrective action was completed.

Task Not Complete

12 High severity numbers were revised when a design change was completed.

Task Not Complete

13 Causes have been described in terms of something that can be fixed or controlled.

Task Not Complete

14

Task Not Complete



Resp. Initials

The Process FMEA was prepared using the AIAG guidelines for severity, detection and occurence.

All the operations affecting fit, function, durability, governmental regulations, and safety have been identified.

Appropriate corrective actions have been planned or taken for high risk priority numbers.

Appropriate corrective actions have been planned or taken for high dectection numbers.

Appropriate corrective actions have been planned or taken for high occurence numbers.

Where detection is the major factor, provisions have been made to control the cause prior to the next operation.

PFMEA

Please place a copy of the PFMEA in this area

Equipment Checklist



1 The assembly equipment sources have been selected.

Task Not Complete

2 The assembly equipment design has been kicked off.

Task Not Complete

3 The equipment design provides for quick change.

Task Not Complete

4 The equipment design can accommodate fluctuations in volume.

Task Not Complete

5 Process safety was a consideration in the equipment design.

Task Not Complete

6 The equipment design includes provisions for mistake proofing.

Task Not Complete

7

Task Not Complete

8 The assembly equipment build has been kicked off.

Task Not Complete

9 A timeline with sufficient equipment detail has been submitted to the customer.

Task Not Complete

10 A list has been prepared identifying all new equipment specific to the project.

Task Not Complete

11

Task Not Complete

12

Task Not Complete

13 Preliminary capability study will be conducted at the equipment manufacturer.

Task Not Complete

14 The feasibility and accuracy of new test equipment has been established.

Task Not Complete

15

Task Not Complete

16 A spare parts list has been identified.

Task Not Complete

17 The receipt of Equipment includes a set(s) of initial spare parts.

Task Not Complete

18 The setup instructions for new equipment are complete and understandable.

Task Not Complete

19 The process characteristics that affect key quality characteristics have been identified.

Task Not Complete

20

Task Not Complete

21

Task Not Complete

22

Task Not Complete



Resp. Initials

The new equipment was designed and will be built to corporate engineering standards, using standard components.

The supplier and equipment contractor have a written acceptance criteria for new equipment.

Certified checking fixtures will be available at the assembly equipment source for part run offs.

A preventive maintenance plan has been started for equipment, including daily, weekly, monthly and annual inspections.

Capability or 100% mistake proofing of the key quality characteristics was used in determining acceptance criteria.

The manufacturing equipment has sufficient capacity to handle forecasted production and service volumes.

In-house testing & measurement capacity is sufficient to provide adequate support for PPAP and problem solving.

Supplier Inspection Instructions

Gauge Plan

Gauge design approval

Gauge Checklist



1 The gauge sources have been selected.

Task Not Complete

2 The gauge designs have been kicked off.

Task Not Complete

3

Task Not Complete

4 Key quality characteristics have been incorporated into the gauge design.

Task Not Complete

5 Process safety has been considered in the design of the gages.

Task Not Complete

6 The Gage Plan has been completed and signed off by the SDE.

Task Not Complete

7 The gage builds have been kicked off.

Task Not Complete

8 A timeline with sufficient gage detail has been submitted to the customer.

Task Not Complete

9 The gage (s) will be complete and certified in time for the first off-tool parts.

Task Not Complete

10 The gage (s) will be complete and certified in time for the assembly equipment buy-off.

Task Not Complete

11 A GR&R has been planned at the Gage builder using prototype or similar parts.

Task Not Complete

12

Task Not Complete

13

Task Not Complete

14 The maximum allowable GR&R error (% of tolerance) is per AIAG Guidelines.

Task Not Complete

15 Work instructions for gage use will be written and available for the Part PPAP review.

Task Not Complete

16 Job training includes instruction on proper use and care of gages.

Task Not Complete

17

Task Not Complete

18

Task Not Complete



Resp. Initials

The NTG Gauge Manual was used to develop specifications for the gage design. If not, list exceptions.

The type of gage certification required has been agreed upon with the SDE (3rd Party, gage supplier/part supplier, customer certification).

The AIAG Measurement System Analysis GR&R method will be used to determine gage error.

Grain / Paint / Chrome Standards are at location and verified to proper level (Color code and spray date).

All gages are correlated. The parts are able to be layed out with the fixture or correlation studies between the check gages and the CMM holding fixture will be completed and necessary corrections made.

Control Plan Checklist



1

Task Not Complete

2

Task Not Complete

3

Task Not Complete

4

Task Not Complete

5

Task Not Complete

6

Task Not Complete

7 All gauges and test equipment, as required by the control plan, are available.

Task Not Complete

8

Task Not Complete

9 Lot Traceability is verifiable.

Task Not Complete



Resp. Initials

All Significant Product Characteristics (SPC's) and Special Process Characteristics are included in the control plan.SC's are noted on the control plan with a Diamond <D>.

All Critical Characteristics realated to safety, FDA regulations, are identified per GMP. Special Characteristics symbols used as requirments.

Each line f the control plan has an asspciatied reation plan to aid in containment, process correction and process re-validation.

Annual re-validation requirements have been agreed with are included on the control plan.

Features that are mistake proofed are easily identified in control plan or the supplier has completed the Mistake Proofing Matrix.

A sensor / fixture verification audit is performed on a regular basis to verify that all mistake proofing details are working properly.

A review of measurement methods between the supplier and customer has taken place to assure compatibility.

Control plan

Pre Launch Control Plan Checklist


Requirements Comments/Actions Required Task Status Resp. Initials Due Date

1 All characteristics listed in the pre-launch control plan are being checked 100%.

2 The inspection methods for each characteristic are listed and approved by the SDE.

3

4

5

6

7

8 All gauges and test equipment, as required by the pre-launch control plan, are available.

9



Task Not Complete

Task Not Complete

The format for reporting the measurement/inspection results for trial parts have been reviewed with and agreed to by the SDE.

Task Not Complete

All known customer concerns have been identified to facilitate the selection of key quality characteristics and special process characteristics.

Task Not Complete

All special characteristics (SC's) and special process characteristics are included in the pre-launch control plan.SC's are noted on the pre-launch control plan with a <D>.

Task Not Complete

The pre-launch control plan addresses all incoming (material/components) through processing and assembly, including packaging and shipping.

Task Not Complete

Engineering performance testing requirements are identified on the pre-launch control plan.

Task Not Complete

Task Not Complete

All Critical Characteristics realated to safety, FMVSS regulations, are identified per AIAG Special Characteristics sybols per end used requirments. Supporting documantation to safety items will be submitted per shipment.

Task Not Complete

Pre-Launch Control Plan

Measurment report for sample / trial runs

Product / Process Quality Checklist



1 The supplier has identified who will be the Quality Engineer with the customer.

Task Not Complete

2 The supplier has identified who will be the Quality Engineer with its suppliers

Task Not Complete

3 A Process/APQP Audit has been performed by Strata (Sections 1, 3, 4, 6 & 21).

Task Not Complete

4

Task Not Complete

5 Is there a First off/Last off (FO/LO) procedure to insure part quality shift to shift.

Task Not Complete

6 Sufficient personnel are available to cover all layout & testing requirements.

Task Not Complete

7 Sufficient personnel are available to cover all problem solving analysis.

Task Not Complete

8

Task Not Complete

9 Standard operator instructions are available at each operation.

Task Not Complete

10

Task Not Complete

11

Task Not Complete

12 Detailed Layout/Inspection instructions are available.

Task Not Complete

13 5S or other housekeeping measures are an integral part of the workplace.

Task Not Complete

14 There is a documented training program that includes all employees.

Task Not Complete

15

Task Not Complete

16 There is a documented training program that provides a training schedule.

Task Not Complete

17

Task Not Complete

18

Task Not Complete

19 Training has been completed for other topics as identified. Please list.

Task Not Complete

20

Task Not Complete

21 There is an effective root cause analysis system in place.

Task Not Complete

22

Task Not Complete

23

Task Not Complete

24 Forms are available for appropriate personnel to record layout/inspection results.

Task Not Complete

25 Provisions have been made to place inspection gages at the monitored operation.

Task Not Complete

26

Task Not Complete

27

Task Not Complete

28 Provisions have been made to place inspection logs at the monitored operation.

Task Not Complete

29

Task Not Complete

Resp. Initials

The manufacturing location has a quality certification. By Which Standard? Last certification date? Next Certification date?List the dates for Certification to EN AS 9100 & ISO 14001 in comments box (if applicable).

Each operation is provided with machine or process instructions that are keyed to the process flow chart & control plan.

Visual aids (pictures or diagrams) are included in the Standard operator instructions.

Operators and team leaders were involved in developing standard operator instructions.

There is a documented training program that lists who has been trained on particular job functions.

Training has been completed for statistical process control and statistical methods, such as capability studies, trend analysis & pareto charts.

Training been completed for some type of disciplined problem solving (8-D, 7-step, etc..)

There is a procedure to implement, maintain and establish reaction plans for abnormal production conditions, such as processes being outside of control chart limits (including molding perimeters).

Provisions have been made to place the latest drawings and specifications at a point of accessibility.

Drawings, catia files and specifications are controlled so as to prevent access to obsolete or unreleased documentation.

Provisions have been made to place gage instructions at the monitored operation.

Provisions have been made to place reference or limit samples at the monitored operation.

Provisions have been made to certify and routinely calibrate gages and test equipment.

Product / Process Quality Checklist30 Required measurement system capability studies have been completed.

Task Not Complete

31 Required measurement system capability studies are acceptable.

Task Not Complete

32

Task Not Complete

33

Task Not Complete

34

Task Not Complete

35

Task Not Complete

36

Task Not Complete

37 Rework/repair methods are documented and posted at the station.

Task Not Complete

38 There is a procedure to requalify repaired/reworked materials.

Task Not Complete

39 Rework/repair procedures have been approved by the customer.

Task Not Complete

40

Task Not Complete

41 Periodic audits of outgoing products are planned and implemented.

Task Not Complete

42

Task Not Complete

43 Is there a First off/Last off (FO/LO) procedure to insure part quality shift to shift.

Task Not Complete

44

Task Not Complete

45

Task Not Complete

46

Task Not Complete



Layout, inspection equipment and the quality facilities are adequate to provide initial and ongoing layout of all details and components.

There is a procedure for controlling incoming products that identifies characteristics to be inspected.

There is a procedure for controlling incoming products that identifies frequency of inspection and sample sizes.

There is a procedure for controlling incoming products that identifies disposition of nonconforming products.

There is a procedure to identify, segregate and control nonconforming products to prevent shipment.

There is an appropriate Lot Traceability system from raw material to finished product.

First in/First out (FIFO) is practiced and insured during all phases of the material handling process (receiving through shipping).

The Launch Containment Plan (I.e. GP12, etc) has been developed and submitted to the Schefenacker SDE for review.

There is a plan to support Launch Containment Process activites (manpower, supplies & equipment).

The criteria is developed and understood for exiting the Launch Containment Process.

Launch Containment Plan

Floor Plan Checklist



1 The floor plan identifies all the required process and inspection points.

Task Not Complete

2 Areas for all materials, tools, and equipment at each operation are clearly marked.

Task Not Complete

3

Task Not Complete

4 Process and inspection areas are of adequate size and easily accessed.

Task Not Complete

5 Light levels in the Process and inspection areas are acceptable.

Task Not Complete

6 Inspection areas contain necessary equipment and files?

Task Not Complete

7 Part and material Staging Area's are adequate.

Task Not Complete

8

Task Not Complete

9

Task Not Complete

10

Task Not Complete

11 Material is protected from overhead or air handling systems contamination.

Task Not Complete

12 The cell layout is complete and has been approved by a cross-functional team.

Task Not Complete



Resp. Initials

Sufficient space has been allocated for all equipment including storage of dies, gages, dunnage, visual aids, ingredients, sub-assemblies and any sub components.

Non-conforming material areas are of adequate size, can be secured, and are clearly marked.

Inspection points are logically located to prevent shipment of nonconforming products.

Controls have been established to eliminate the potential for an operation, including outside processing, to contaminate or mix similar products.

Purchasing / Supplier Checklist



1

Task Not Complete

2

Task Not Complete

3

Task Not Complete

4

Task Not Complete

5

Task Not Complete

6

Task Not Complete

7

Task Not Complete

8

Task Not Complete

9

Task Not Complete

10 All packaging (production) has been approved, staged and ready for launch

Task Not Complete



Resp. Initials

All sub-suppliers and contractors have been selected for material, components, tooling, gauges, and equipment.

Material & Component sub-suppliers are on schedule with tooling & equipment to support the project timeline and milestones.

Purchase orders have been issued for all material & components to support the start of production trials.

Purchase orders to lower tier suppliers contain terms & conditions relating to quality standards for the sub-suppliers (Cpk, material certification, PPAP level/requirements, standards, PPM, etc.).

Sub-suppliers have submitted current timelines to the suppliers purchasing and project management.

Sub-suppliers have received forecast and ramp-up schedules to support all production trials, system fill, SOP and peak volume demands..

Production level Material has been defined and is it the same material that will be used from the start of the production trials.

The engineering level of the material & components for the start of the production trials match the current released engineering level.

All Material & Component PPAP's with the sub-suppliers are complete and have received full PPAP approval.

Packaging & Material Control Checklist



1 Packaging data forms have been submitted to Strata.

Task Not Complete

2 The Packaging design has been approved by the Strata team.

Task Not Complete

3

Task Not Complete

4 The quantity of containers is sufficient to support system fill and SOP.

Task Not Complete

5

Task Not Complete

6

Task Not Complete

7

Task Not Complete

8

Task Not Complete

9 The Supplier has completed the Self Assessment.

Task Not Complete

TOTAL PERCENTAGE COMPLETE 0%

TOTAL PERCENTAGE OPEN 100%

Resp. Initials

The packaging is sufficient to prevent damage to all parts, particularly those parts with plating, painting, critical appearance criteria.

Alternate containers or packaging has been investigated in case of unforseen circumstances.

The details of part transportation and delivery have been agreed to with the suppliers and customers

The supplier has made all the appropriate contacts to enable a smooth communication flow and conduct necessary business (engineering change control, inventory control, packaging & logistics, service & parts, purchasing, quality, engineering liaison, accou

The suppliers has received forecast and ramp-up schedules to support all production trials, system fill, SOP and peak volume demands..

PPAP Part Checklist



1

Task Not Complete

2

Task Not Complete

3

Task Not Complete

4

Task Not Complete

5

Task Not Complete

6

Task Not Complete

7

Task Not Complete

8 Grained samples have been submitted to Strata.

Task Not Complete

9 Color and gloss samples have been submitted to Strata, if required.

Task Not Complete

10

Task Not Complete



Resp. Initials

Samples parts for the Production Validation (PV) have been secured and PV testing is proceeding to the agreed schedule.

A preliminary Run@Rate has been performed and the production rate is acceptable to meet the launch curve at the necessary quality level.

The tier 1 supplier has reviewed the production capacity at all lower tier suppliers. The production rates are sufficient to meet the launch curve at the necessary quality level.

The Gage Plan has been completed and signed off by the SDE giving approval to use the gage in series production.

Inspections Methods are complete and to the latest engineering level for each shipping unit. Copies are included in the PPAP submission.

The Launch Containment Plan has been agreed by Strata and has been implemented at the supplier.

Pre-grain samples have been submitted to Strata. The supplier has received authorization to grain the tooling.

Process numbers match between Process Flow Diagram, Process FMEA, and Control Plan.

Preliminary Run at Rate

PPAP Element Checklist



1

Task Not Complete

2

Task Not Complete

3

Task Not Complete

4

Task Not Complete

5

Task Not Complete

6

Task Not Complete

7

Task Not Complete

8

Task Not Complete

9

Task Not Complete

10

Task Not Complete

11

Task Not Complete

6

Task Not Complete

7

Task Not Complete

2

Task Not Complete

5

Task Not Complete

3

Task Not Complete

5

Task Not Complete

6

Task Not Complete

7

Task Not Complete

6

Task Not Complete

7

Task Not Complete

Resp. Initials

The PPAP sample parts have been produced to the latest engineering change level and have been shipped to the customer for PPAP approval with necessary data.

All material test results are complete, acceptable and referenced in the PPAP submission.

All components parts and materials have received full PPAP approval from suppliers. All supplier's PPAP's (tier 2) are referenced within the PPAP submission.

A run @ rate has been performed and documented by the NTG SDE. The production rate is sufficient to sustain full series production at published volumes.

The part is being produced at the current engineering release level with no open deviations.

The Process Flow, PFMEA and Control Plan have been updated to reflect the current manufacturing & quality processes.

The Production Validation (PV) Testing is complete and parts from the series tooling & processes meet all known Specifications (Drawing, OEM Specifications, SAE, ASTM, etc..). A summary of the PV test plan and report is included in the PPAP documentation

The Launch Containment Plan has been effective in capturing all defective material at the supplier location.

All PPAP documentation is complete (utilize AIAG guidelines) and the package has been reviewed internally prior to submission to the Customer.

(1) Part Submission Warrant"Part number" is NTG Part Number."Engineering Drawing Change Level" and "Date" is NTG Drawing Level and Date."Shown on Drawing" is NTG Drawing."Weight (kg)" is to four (4) places expressed in kilograms.NTG Supplier Code is

(2) Engineering Change DocumentsAll, if any, applicable NTG Change Control Notices (CCN's) included.If none insert sheet saying not applicable.

(3) Customer Engineering ApprovalAll, if any, applicable NTG Tool Life Deviations (TLD's) included.If none insert sheet saying not applicable.

(4) Dimensional ResultsThe part layouts are acceptable. All dimensions are within tolerance.If no dimensional layout necessary then insert sheet saying not applicable.

A six (6) piece per cality (minimum) part layout is complete. The layout includes 100% of all dimensions (as default) or all of those dimensions agreed with the SDE. All print notes are referenced on layout.

Dimensional results of the part layout are documented in the format agreed with the SDE. Dimensional results are referenced by balloon number on ballooned print (included in PPAP submission).

If necessary, special layout set-ups for dimensions are reviewed and approved by customer before PPAP submission.

(5) Initial Process StudyAll significant and critical characteristics have initial process studies.Sample size is per AIAG Guidelines.If drawing does not contain critical dimension(s) then characterstic to measure shouwl be agreed upon with the Enginee

All required capability studies have been performed and meet requirements of 1.67 Ppk/Cpk.

(6) Measurement System Analysis StudiesA GR&R is performed for every gage used on the control plan, process study.

Gage R&R's have been completed for all checking fixtures and test equipment, associated with the shipping unit, intended for production use.GR&R's are equal to or less than the target as per AIAG Guidelines.

(7) Checking AidsAll checking fixtures associated with the shipping unit are certified and certification is referenced in the PPAP submission.If none insert sheet saying not applicable.

PPAP Element Checklist5 Layouts are included for attribute gaging to verify compliance.

Task Not Complete

6

Task Not Complete

7 Results for Performance Testing are included in PPAP submission.

Task Not Complete

2 A summary of material tests / specifications is included in the PPAP documentation

Task Not Complete

6 Results for Material Testing / Specifications are included in PPAP submission.

Task Not Complete

7

Task Not Complete

5

Task Not Complete

6

Task Not Complete

7

Task Not Complete

2

Task Not Complete

5

Task Not Complete

3

Task Not Complete

8

Task Not Complete

2

Task Not Complete

6

Task Not Complete

7

Task Not Complete

5

Task Not Complete



(8) Material, Performance Test ResultsA summary of the PV test plan and report is included in the PPAP documentation.

Restricted or reportable substances report - appropiate OEM form is included (CS-9000, GM3059, WSS-M99P9999-A1 report).

(9) Qualified Laboratory DocumentationDocumentation is provided showing lab is approved to perform testing (ISO/TS 16949:2002, A2LA, ISO25, etc.).

(10) Design FMEADesign FMEA is included in PPAP submission.If not design responsible, insert sheet saying not applicable.If Design FMEA is propietary, insert sheet saying propietary and only for review at supplier location.

(11) Process FMEAProcess FMEA is included in PPAP submission.If Process FMEA is propietary, insert sheet saying propietary and only for review at supplier location.

(12) Process Flow DiagramsProcess Flow Diagrams are included in PPAP submission.

(13) Control PlanControl Plan is included in PPAP submission.

(14) Appearance Approval Report (AAR)The Appearance Approval Report (AAR) has been completed for grain, gloss & color and accepted by SVS and OEM.

(15) Records of Compliance with Customer-Specific RequirementsA copy of TS/QS/ISO registration is included in the PPAP submission.

(16) Master SamplesMaster samples have been retained by the suppliers for use in making acceptance and boundary samples.Insert sheet in PPAP submission stating master samples retained at supplier.

(17) Sample ProductTwo (2) samples are included in PPAP submission. Samples are to be marked with program, part number, print revision level, and date of PSW (date supplier signed PSW).

(18) Bulk Material Requirements ChecksheetFor bulk material suppliers only. Insert sheet saying not applicable if do not need checksheet.

(19) Design Records of Saleable ProductAll Design records are included in submission.Ballooned print for dimensional results is included in PPAP submission.

document.xls.xls Special - Pass Thru List 47/50 Rev. Date 7/21/06

Supplier - Special / Pass-Thru Characteristics FormOptional Form

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Impact of FailureSpecial or Pass Through Characteristic

Prevention:

Detection:

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Prevention:

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Prevention:

Detection:

Prevention:

Detection:

Prevention:

Detection:

Prevention:

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document.xls.xls Special - Pass Thru List 48/50 Rev. Date 7/21/06

Supplier - Special / Pass-Thru Characteristics Form

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Current PFMEA Process Controls

Target Date

document.xls.XLS definitions 49/50 Rev. Date: 7/21/06

DEFINITIONScontrolled document in accordance to FDA & National Regulations

Risk/Status AssessmentRisk Color Definition

High Red

Moderate Yellow

None Green Target dates and deliverables are on track and meeting objectives.

Form RequirementsForm Process Required/Optionoal Form Required/OptionalAPQP R R

Open Issues R OMeeting Log O OFeasibility R O

Pass Through O O

Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work plan does not achieve program targets.

Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieveprogram targets, and has been approved by the appropriate Management Team

document.xls.XLS definitions 50/50 Rev. Date: 7/21/06

DEFINITIONScontrolled document in accordance to FDA & National Regulations

Risk/Status AssessmentDefinition

Target dates and deliverables are on track and meeting objectives.

Form RequirementsForm Required/Optional

ROOOO

Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work plan does not

Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieveprogram targets, and has been approved by the appropriate Management Team

APQP Checklist Report.version 1.1.Dtd. 13.11.08

Documents

Transcript of APQP Checklist Report.version 1.1.Dtd. 13.11.08