APQP Workbook

7/23/2019 APQP Workbook

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Supplier APQP: Four Phases

APQP -> Phase 1 APQP -> Phase 2 APQP -> Phase 3

Supplier Kick-Off and Planning Product/Process Realization Pre-PPAP

Identify MEI and Supplier team

contacts/roles/responsibilities

Create and/or review DFMEA as appropriate

depending upon design resp.Pre-production run

Communicate and initiate Key Supplier Metrics Develop process flow chart (diagram). Process capability study

Initial Supplier Program plan and timingCreate & review preliminary process flow

diagram, PFMEA, and Control Plan.Finalize PCM: prepare for Safe Launch

Conduct Cross-functional component design

review (doc is located in GSQM)

Finalize PCM & use document for any pre-

product part runs.Finalize PFMEA and Control Plan

Create preliminary Product Characteristics Matrix

(PCM) - Safe Launch PlanConfirm tooling and gage construction progress. Review Supplier Ramp Plan

APQP Requirements Develop Process Instructions Launch Readiness Audit: document key met

Equipment Tooling & gage concept/design

review.Finalize Process capability study Plan

Re-qualify equipment, tooling & gaging as it

moves between supplier site(s)

Review MEI PPAP Requirments with the supplier

(per MEI PPAP Checklist)

Validation review of "1st Off" tool/part

condition(s). Address any issues that can't becontained w/n program timing. Appearance Approval (as appropriate)

Review supplier's manufacturing feasibility

document(s)Floor plan layout Supplier participates in Plant Readiness Rev

Review preliminary capacity study & initial

supplier master schedule plan

Update previous phase open issues and key

documentsReview status of Key Supplier Metrics

Iniate Open Issues DocumentUpdate previous phase open issues and key

documents.

A= MEI SDE will coduct APQP 1 - 4 w/ Supplier

B= MEI SDE will conduct APQP 1 and 4 w/ Supp

C=

PPAP only to SDE. Supplier is still responsib

maintaining APQP 1-4.

Component Criticality Rating

Magna Electronics (MEI) - 4 Phases of APQP for Supplier Develo

Date: 14 May, 2008

Rev. A Magna Electronics APQP Woorkbook


2/20

Product

Characteristics Matrix -

Tier II

The PCM is used initially to define and determine appropriate controls for special characteristics, other process critical

features and customer touch points. This tab is used to define the process at MEI's direct supplier. Throughout the APQP

phase of launch this form is used as the Pre-Launch Control Plan and also forms the basis for Safe Launch Planning.

Product

Characteristics Matrix -

Sub-Supplier

The use of this tab is identical to the functionality define above, with the exception that this is used to document the

remaining supply chain's, below the Tier II supplier, impact on the critical features.

Open Issues The action plan format used to document open issues, their actions and resolution throughout the APQP process. This

combines several different action plans generated by different, individual tools into a single document.

Contacts Lists the individuals involved in the component(s) launch, for both MEI and the supplier, and their respective contact

information. This tab is optional and may be used as needed.

Key Metrics Definitions Operational definitions for the twelve key metrics. Explains the metric and its method of calculation.

MEI PPAP Checklist &Document ".ZIP"

Folder

It is an expectation of MEI that the PPAP Checklist is used for each new part submission to make sure that all requiredPPAP elements are submitted free of the errors that have been historical observed. MEI is confident that if the PPAP

Checklist is used that it will help insure expedited PPAP approval. Please use the embedded PPAP ".ZIP folder" to

make sure that all required PPAP elements are submitted in a softcopy format that helps with ease of review and

document storage.

Format to be used for a weekly summary of the inspection results from the Safe Launch Plan. This information will be

used as part of the decision making process for the removal of the Safe Launch Controls.

PCM - Weekly QOS

Report

Supplier APQP: Table of Contents

Blank Time Line Suppliers are required to create a Master Time Line for the launch of the awarded component(s). It is expected that a

Gantt chart is used as the format. For those suppliers who do not have software available to meet this requirement, a

blank time line is provided for their use.

Shows the 4 APQP Phases and the activities that occur within them.Cover

Table of Contents Lists all of the forms and examples included in this workbook. The Worksheet with "Tabs" highlighted in YELLOW require

supplier documentation and reporting back to MEI SDE.

Supplier FeasibilityStatement

In accordance with The Automotive Industry Action Group (AIAG) and OE specific requirements, the supplier's teamfeasibility commitment document initiates the MEI APQP process. Unless exceptions or concerns are communicated to

MEI as part of the quoting process it is the assumption that the supplier will be providing product that is fully compliant to

all applicable drawings and specifications.

Supply Chain Map Form for showing multi-tier supply chain relationships involved in providing the component/assembly to MEI. The

information documented here will also be used in the creation of the Product Characteristics Matrix (PCM).

Key Metrics Report Key Metrics contain those elements that contribute to a successful launch. This form allows for four reviews. The

minimum requirement is to use the first two columns at APQP-2 and APQP-4. The APQP-3 report is generated during the

first parts off run at the supplier's manufacturing location. This establishes a baseline performance on the process in its

"as received" state. The APQP-4 report is generated at the time product is manufactured for the PPAP submission. Theadditional columns would either be used at the discretion of the SDE or based on circumstances that require additional

reviews.

Supply Chain Map

Example

An example of how a Supply Chain Map may appear for a typical metal component.

Date: 14 May, 2008

Revision: A

Magna Electronics APQP WorkbookProcess Owner/Department:

Chris Hempsall

Approved by:

Justin Reaume


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Part No.: Date: ________________

Rev. No.:

YES NO

ll

l

l

l

Conclusion:

Feasible

Feasible (Conditional)

Not Feasible > Design revision required to produce product within the specified requirements.

Issue # Open Close

Name: Name:

Title: Title:Signature:

Date: Date:

Name: Name:

Title: Title:

Date: Date:

Considerations

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

Can Engineering Performance Specifications be met as written?

Review Considerations:

Supplier Design Review Sign Off

Part Name:

Can product be manufactured without incurring any unusual:

Costs for capital equipment?Costs for tooling?

Alternative manufacturing methods?

Can product be manufactured to tolerances specified on drawing?

Can product be manufactured with Cpk's that meet requirements?

Is there adequate capacity to produce product?

Does the design allow the use of efficient material handling techniques?

Are Cpk's greater than 1.33?

Is the appropriate packaging available to protect the product during shipment? (Provide a proposal)

Are special / uncommon materials required that are not readily available?

> Product can be produced as specified with no revisions.

Is statistical process control required on product?

Is statistical process control presently used on similar products?

Where statistical process control is used on similar products:

Are the processes in control and stable?

Corrective Actions / Resolution Plan

Signature:

Sign-Offs:

Magna Electronics Supplier _____________________________

Signature: Signature:

ME and supplier product quality planning team has considered the following questions, not intended to be all-inclusive in performing a feasibility

evaluation. The drawings and / or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All

"no" answers are supported with attached comments identifying our concerns and proposed changes to enable us to meet the specified requirements.

> Changes recommended (see issues list below).

Issues / Comments / Risks


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02

04

06

08

10

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

42

44

46

48

50

52

02

04

06

1.1 Design FMEA

1.2 Preliminary Capacity Study reviewed

1.3 Manufacturing Feasibility reviewed

1.4 Component Design Review

Product Characteristic Matrix initiated

1.5 Key Supplier Metrics initiated

1.6 Supplier Project timing plan

1.7 Open Issues Action Plan created

2.1 Measurement/ Testing equipment2.2 Preliminary Process Flow Chart Review

2.3 Preliminary PFMEA Review

2.4 Preliminary Control Plan Review

2.5 Tool ing

2.6 Capital equipment

2.7 Training

2.8 Process instructions

2.9 Packaging

2.10 Key Supplier Metrics reviewed

3.1 ELV/IMDS

3.2 Safe Launch Plan (PCM) finalized

3.3 Sub-Supplier PPAP Approvals

3.4 Supplier Ramp Plan

3.5 Plant Readiness Review3.6 Launch Readiness Audit

3.7 Appearance Approval Process (when applicable)


4.1 PPAP

4.2 Launch Readiness Audit

4.3 Run at Rate


4.5 OK to Launch Sign-Off

5.1

5.2

5.3

5.4

5.5

5.6

5.7

KEY: X Planned start O Planned completion + Act

Supplier APQP: Four Phase Time Line (EXAMPLE)

APQP

PHASE

OUTPUT

Year 1

3.

Pre

-PPAP

4.

Product/

Process

Validation&

5.

Other

Requirements

The Magna Electronics Supplier Advanced Product Quality Planning (APQP) process consists of 4 Phases. Essential to this process are 12 Key Supplier Metrics (KSM).

reviewed during each of the following phases. The time line below illustrates the relationship between the 4 Phases, their deliverables and the Global Development & Prod

This workbook consists of 9 forms in support of this process (the respective tab colors are highlighted in "yellow"). Suppliers are expected to use this process regardless oa PPAP package.

1.

SupplierKick-Off

2.

Product/Production

Realization

Magna Electronics APQP Workbook


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02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 02 04 06 0 8

1.1 Design FMEA

1.2 Preliminary Capacity Study reviewed

1.3 Manufacturing Feasibility reviewed

1.4 Component Design Review

Product Characteristic Matrix initiated

1.5 Key Supplier Metrics initiated

1.6 Supplier Project timing plan

1.7 Open Issues Action Plan created

2.1 Measurement/ Testing equipment

2.2 Preliminary Process Flow Chart Review

2.3 Preliminary PFMEA Review

2.4 Preliminary Control Plan Review

2.5 Tool ing2.6 Capital equipment

2.7 Training

2.8 Process instructions

2.9 Packaging


3.1 ELV/IMDS

3.2 Safe Launch Plan (PCM) finalized

3.3 Sub-Supplier PPAP Approvals


3.5 Plant Readiness Review


3.7 Appearance Approval Process (when applicable)


4.1 PPAP


4.3 Run at Rate


4.5 OK to Launch Sign-Off

5.1

5.2

5.3

5.4

5.5

5.6

5.7

KEY: X Planned start O Planned completion + Actu

5.

Other

Requirements

3.

Pre-PPAP

4.

Product/

Process

Validation

&

1.

SupplierKick-Off

2.

Product/Pr

oduction

Realization

Supplier APQP: Blank Time Line

AP

QP

PHASE

OUTPUT

Year 1


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Enter the number ofGREEN elements at

the time of the report.

Enter the total number of elements being

tracked. There are 34 elements on the

APQP Progress Report. For suppliers

where the DFMEA does not apply subtract

1. For suppliers who are not providing an

Appearance item, subtract 1.

Enter number of completed processinstructions at the time of the review.

Enter total number of process instructions

needed for serial production.

Enter, as a decimal number, the ratio of

total parts produced to good parts from

the trial run.

Enter the number '1,' which represents the

production of 100% good, or usable, parts.

The amount of available capacity at the

time of the review. Enter result as a

decimal number.

The minimum amount of available capacityshould be 15% (85% utilization). Enter

0.15

Enter the number of characteristics, with

a Ppk > 1.67, at the time of the review.

Enter the total number of designated

characteristics on the drawing.

This is the total number of samples that

passed all of the required testing at the

time of the review.

The should represent the total number of

individual tests required times the number

of samples, for each test, that is required.

Total number of set-up, manufacturingand inspection instructions needed.

Process Efficiency Measured in available capacity.

Expectation for open capacity is 15%

minimum. This is achieved by dividing

Takt time into cycle time and subtractingthe result from 1.

Results

APQP Readiness

DefinitionMetric

Data is derived from the 'APQP Progress

Report'. This metric tracks the

percentage ofGREEN elements

compared to the total number of

elements being tracked.

Process Instructions

APQP: Key Supplier Metrics Operational Definitions

First time Capability Percentage of good parts to the total

number of parts produced during the Run

at Rate.

Test Achievement Total number of performance and

materials tests that need to be conducted

to meet the specifications shown on the

drawing. This number is a combination

of the number of unique tests multiplied

by the number of samples required for

the test.

This section defines the Key Supplier Metrics that will be tracked throughout the four APQP Phases. Reviews will be held toward the end of each of the four

phases. Review of these metrics, in the Phase 4, will take place before the final full PPAP approval

Process Capabil ity The number of designated

characteristics with a Ppk > 1.67.

Goal


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Results

DefinitionMetric




Goal

Enter the appropriate stage of process

implementation in regard to

manufacturing for serial production.

1. Prototype process is implemented; No

released deviation of concession; No

containment plan.

2. Interim process implemented, with

partial production intent process; No

released deviation or concession; No

containment plan.

3. Prototype or partially implemented

process; Released deviation or

concession; No containment plan.

4. Partial or fully implemented process;

Released deviation or concession;Containment plan implemented.

5. Fully implemented process; No

deviation or concession required

5. Fully implemented process; No deviation

or concession required.

The score achieved on the Launch

Readiness Audit. Enter data as a

decimal number.

The minimum goal for full release for

production is 90%. Goal is 100% and

entered as "1".

The number of approved sub-component

and material PPAPs at the time of the

report.

The number of approved sub-component

and materials making up the shipped

component/material.

The number of elements (or documents)

completed for the PPAP package at the

time of the review.

The total number of required elements, or

documents, required to be submitted.

PPAP Package

Completion

Number of PPAP submission package

elements completed compared to

required number.

Launch Readiness Audit

This metric assesses the level of

implementation of the full production

intent process. Processes that are not

fully implemented at the Start-of-

Production require a deviation, or

concession, to allow shipment. This

document needs to clearly define the

state of the process implementation,

provide a time line for completing the

implementation, list any non-conformities

to the drawing and/or specifications, and

a containment plan to keep those non-

conformances from reaching MEI.

Process Implementation -

% Completed

Sub-Component PPAP

Approvals

Number PPAPs approved for the

purchased sub-components and

materials that makes up the final shipped

component/material, and that do not have

any deviations, waivers, and/or

concessions granted by any tier below

MEI.

A comprehensive audit tool's score,

which assesses a process's state of

preparation to meet serial production

requirements.


8/20

Results

DefinitionMetric




Goal

Enter the number corresponding to the

completed stage from the list below.

1. Has not received any production

releases from using plant(s).

2. Is receiving production releases from

the using plant(s), but no production

schedule or plan documented to meet

those volumes orhas ramp plan, is

receiving plant releases, but is not

shipping to plan and/or releases .

3. Has not received production releases

from plant(s), but has created a

preliminary planned based on quoted

volumes and program timing.

4. Is receiving production releases andhas created a plan, but production

schedule does not reflect the plan.

5. Is receiving production releases, has

created a ramp plan and this plan is

reflected in the production schedule.

Enter the goal, Level 5-Is receiving

production releases, has created a ramp

plan and this plan is reflected in the

production schedule.

Enter number of completed stage at time

of review.

Enter the number '5' representing the

completion of the PCM, less the exit from

the Safe Launch Plan. This applies to

situations where the PPAP will be

submitted in a span of time from before

SOP to 30 days after SOP.

Enter the number '6' for situations where

the SLP exit is required for closing APQP.

Completion of the PCM is noted by

Operations, i.e., plant, approval of the

Safe Launch Plan portion of the form.

Stages of completion are:

1. MEI's supplier has completed the

form, less SLP.

2. MEI's supplier has completed their

sub-supplier form, less SLP.

3. Supplier section completed, including

SLP.

4. Sub-supplier section completed,

including SLP.

5. Characteristic Review signed off on

both tabs.

6. Complete sign-off on both tabs for

"Safe Launch Exit Approval.

Supplier Ramp Plan

Safe Launch Plan (PCM)

Deployment

This element evaluates a supplier's ability

to meet ramp-up timing and volumes.


9/20

Supplier Name: Supplier Location: Supplier Code:

Part Number: Part Name: Revision Level:

Component Priority Level: Lead Customer/Program: Report Date:

SUPPLIER SIGN-OFF (MANAGER LEVEL)

MEI SIGN-0FF

Results

#DIV

Goal

TargetProduction Preparation Influencing Factors

Number of PPAP required documents required

Complete Stage 5 by SOP 5

Primary Indicator:

Enter completed stage of PCM (see comments)

Total number of instructions completed

Ramp planned completed and shipping to releases

Available capacity based on % of cycle time to Takt time

achieved

Maximum acceptable % of available capacity base on %cycle

time to Takt time

Total number of purchased sub-components/materials

State of completed supplier ramp plan

Number of PPAP required documents completed

Total number of elements from 'Progress Report'

Number of sub-components and materials PPAP approved

Number of capable designated characteristics features

Score achieved during event

Goal is 100%.

1. APQP Readiness

2. Process Instructions

6. Test AchievementNumber of tests passed

7. Process Implementation -

% Completed

% of total tests

Number of 'Progress Report' elements with Green status

5

MANUFACTURABILITY

Total number of designated characteristics features

Results from Run at Rate

Ideal % of good parts3. First Time Capability

Total number of instructions needed.

Production volumes provided off production intent process

High volume process or Interim Process wi th Concession

5

Production ControlPurch/Sales Quality DesignEngineering

#DIV/0!Metrics Overall Score #DIV/0! #DIV/0!

Signature

Name (print)

9. Sub-Component PPAP

Approvals

10. PPAP Package

Completion

11. Supplier Ramp Plan

Man

8. Launch Readiness Audit

5. Process Capability

12. Safe Launch Plan (PCM)

Deployment

MEI Internal Use only Commodity Mgr/Buyer

SDE

SQA

Function Project Leader

DLN

K

E

Y

M

E

A

S

U

R

E

A

B

L

E

S PPAP

Supplier APQP: Key Supplier Metrics Report

Signature

Signature

Name (print)

Name (print)

Name (print)

Signature

4. Process Efficiency


10/20

Precision Forming

Amarrillo, TX

Airbag Reaction Can

49019804A

Stamping body, end

caps, brackets

TIER 4

SUPPLIER

TIER 2

SUPPLIER

TIER 3

SUPPLIER

Anaconda Steel

Erie, PA

C1038 Rod

Steel Mill

Zephyr Coatings

Austin, TX

E-Coat

Dynamic Chemical

Supplies

Tulsa, OK

Coating materials,

solvents

White & Jones

Jackson, MI

C1038 Rod

Wire Draw, Anneal

Fine Fasteners, Inc.

Benton Harbor, MI

M8x20 Weld Stud

59039813A

Cold Forming

B&C Processing

Georgetown, PA

C1024 RodWire Draw, Anneal

ABC Nut Co.

Summit, NJ

M8x15 Staking Nut

59039812C

Cold Forming

AAA Heat Treat

Frederick, MD

Harden & Draw

Kojak Heat Treat

Benton Harbor, MI

Harden & Draw

Supplier APQP: Supply Chain Map - Example

TIER 1 SUPPLIER

Pacific Steel

Los Angeles, CA

C1024 RodSteel Mill


11/20

Supplier: Part Number: Date: Revision:

TierTier IIME Receiving

Operation

OEM

Customer

upplier APQP: Supply Chain Map

Tier V Tier IV Tier III


12/20

Part Name: Supplier

Part Number/ Revision: Lo

Project/ Program: MEI Using P

Design CharacteristicLevel/

Class

DFMEA

Sev.

PFMEA

Occ.

PFMEA

Det.RPN Control Method/ Equipment

Date

MEI SDE

MEI Plant SQA

Supplier Representative

Date

MEI SDE

MEI Plant SQA

Ch

#

MEI/ Supplier

Name

Name

Position/ Title


Position/ Title

TIER II - S

Supplier APQP: Product Characteristic Matrix


13/20

Part Name: Supplier Name:

Part Number/ Revision: Location:

Project/ Program: MEI Using Plant(s):

Design CharacteristicLevel/

Class

DFMEA

Severity

PFMEA

Occurrence

PFMEA

DetectionRPN Control Method/ Equipment

Gauge

R&R

% Tol

Pp/ Ppk Freq./Size Con

Date

MEI SDE

MEI Plant SQA


Date

MEI SDEMEI Plant SQA

Sub-Supplier Process Control

Signature

Signature

Position/ Title


Position/ Title

Safe Launch Exit A pprovals

Character ist ic Review Ap proval

#

TRW/ Supplier

Name

Name

Supplier APQP: Product Characteristic Matrix (Sub-Supplier)


14/20

Total WEEK W14

71 Incidents 65

9350 QTY 2350

7594 PPM 27660

FaultNo.

Failure Mode Total Action Timing W14

13 Abutment hole diameter 11 11

2 Lining wear inspection hole diameter 10 10

14 Nut thread check 7 7

8 Wheel cylinder hole position 6 6

3 Adjuster hole diameter 5 5

6 Bearing case ID 5 5

7 Wheel cylinder hole diameter 5 5

5 Mounting holes diameter 4 4

9 Brake cable hole position 3 3

11 Threaded nut hole position 3 321 NO paint scratch and or contamination, Blistering, runs 2 2

12 Abutment hole position 2 2

20 No Cracks on backplate (visual boundary sample) 2 2

16 Abutment and locating plate gap 0 0

10 Brake cable hole diameter 0 0

19 Locating abutment plate smooth surface 0 0

17 Dust ring gap to backplate check 0 0

18 Cable guide gap 0 0

4 Mounting holes position 0 0

15 Nut weld torque 0 0

1 Hold down pin diameter 0 0

Safe Launch Plan: Weekly QOS Report

0

5000

10000

15000

20000

25000

30000

0

10

20

30

40

50

60

70

W14 W15 W16 W17 W18 W19 W20 W21 W22 W23 W24 W25 W26 W27 W28 W29

Incident

Touch Point Incident & PPM Monitoring

Incidents PPM

Example


15/20

Supplier Name: Component Manufacturing Location: Supplier Code:

MEI Part Number(s): Issued by:

Customer Name: Customer Platform: MEI Product: Status:

Action plan review

Distribution:

Status

Da

Launch ActivityLaunch Activity Date Date Launch Activity Date

Source of IssueConcern / Problem / Open Issue

Description

Dates

Date scheduled Date actual

DueOpened

Supplier APQP: Open Issues - Corrective Action Plan

Item

NumberAction

Closed


16/20

Supplier Name: Supplier Location: Supplier Code:

Part Number: Part Name: Revision Level:

Component Priority Level: Lead Customer/Program: Report Date:

PROGRAM MILESTONES

PHASE/ELEMENT STATUS OVERVIEW

20

40

60

80

100


Key Supplier Metrics reviewed

3.6Appearance Approval Process

(when applicable)

3.4

Packaging


APQP

PhaseStatus

Element Issues / Recovery Plan

DatePercent

Complete

Needed Committed Complete

Manufacturing Feasibility reviewed

C

PPAP submission

Start of Production

ME PV Build

1

3

Date Date

CommittedEvent Event

Design Freeze

Needed Committed Completed Needed

4

Design FMEA

Preliminary Capacity Study

reviewed

2

First Off-Tool

Capital equipment

Measurement/ Testing equipment

Key Supplier Metrics initiated

Supplier Project timing plan

Open Issues Action Plan created

First Off-Process

PPAP



ELV/IMDS

Safe Launch Plan finalized

Plant Readiness Review

2.3

Run at Rate

OK to Launch Sign-Off

1.1

1.2

1.3

1.5

1.6

1.7


3.1

3.2

2.12

2.11

2.1

2.2

2.4

2.9

2.5

2.7

Component Design Review

4.5

3.7

4.1

4.2

4.3

4.4

2.1

2.13

Training

Process instructions

Supplier APQP: Progress Report - Status Overview

1.4

Sub-Supplier PPAPs


Tooling

Initiate PCM (Safe Launch Plan)

2.6 Process Flow Diagram

2.8 Control Plan

PFMEA


17/20

Magna Part Number: Description: Revision Level:

Customer: Program: Product Line:

Company Name: Product Line:

Company Location: Using Location:

Supplier Code: Reviewer:

Contact Name: Phone: Review Date:

Contact email: Disposition:

No. 1 2 3 4 5

1 S S S S R

A.

B.

C.

D.

1.

2.

3.

E.

F.1.

G.

H.

1.

2.

I.

J.

2 R S S * R

A.

B.

3 R S S * R

A.

B.C.

D.

E.

4 R R S * R

A.

5 R R S * R

A.

B.

C.

D.

6 R R S * R

A.B.

C.

7 R R S * R

A.

B.

C.

D.

E.

8 R S S * R

PPAP Submission Checklist

SUPPLIER INFORMATION MAGNA ELECTRONICS INFORMAT

Document

Part Submission Warrant

PART NUMBER INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT

WEIGHT INCLUDED

SUPPLIER MANUFACTURING INFORMATION COMPLETE, INCLUDING SUPPLIER CODE

PPAP

Submission

Level

A

Required

ELV/IMDS INFORMATION INCLUDED: The Magna Holly IMDS # is 9822

CORRECT REASON FOR SUBMISSION BOX CHECKEDIF OTHER IS CHECKED, THAT THE CORRECT REASON FOR SUBMISSION IS NOTED

CORRECT SUBMISSION LEVEL BOX IS CHECKED

SUBMISSION INFORMATION COMPLETE.

ALL APPROPRIATE BOXES CHECKED

BUYER NAME INCLUDED

APPLICATION INFORMATION INCLUDES MAGNA CUSTOMER AND PROGRAM

SIGNATURE AREA IS COMPLETED AND CONTAINS ALL INFORMATION

Design Records (Drawings, Specifications)

A MARKED OR BALLOONED DRAWING IS ATTACHED. Note: All non reference print items and specs must be addressed.

COPIES OF ALL REFERENCED SPECIFICATIONS ARE INCLUDED IN THE SUBMISSION (LEVEL 3 ONLY)

THE SUBMISSION RESULTS AREA IS PROPERLY FILLED OUT AND THE PACKAGE REFLECTS THIS

PACKAGE CONTENTS MUST REFLECT SUPPLIER'S STATEMENT OF COMPLIANCE

FOR MULTIPLE TOOLS/CAVITIES/PROCESSES THAT THE INFORMATION IS NOTED IF APPLICABLE

THE DECLARATION AREA CONTAINS THE RUN AT RATE INFORMATION

ACTION PLAN INCLUDED IF REQUEST IS FOR DEVIATION/CONCESSION

SIGNED AND DATED BY MAGNA ENGINEERING

Customer Engineering Approval Documents

IF PROCESS INCORPORATES UNRELEASED CHANGE, COPY OF ENGINEERING DOCUMENT INCLUDED

Change Documents

PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT

PART APPLICATION / PROGRAM / PLANTS IDENTIFIEDSPECIFIES TIME SPAN OR VOLUME AFFECTED

AREAS OF CONCERN IDENTIFIED IN THE DFMEA ARE CARRIED OVER INTO THE PFMEA.

Process Flow Diagram

PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECTMUST START WITH RECEIVING AND FINISH WITH SHIPMENT OF MATERIAL

Design FMEA

PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT

DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART?

DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT?

WHERE APPROPRIATE, DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT?

ARE CONCERNS INCLUDED THAT WERE DISCOVERED IN EARLY STAGES?

CRITICAL FEATURES IDENTIFIED ON THE PCM/SLP, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS,

CRITICAL PROCESS CONTROLS, ETC.) ARE INCLUDED IN THE PFMEA AND HAVE RPN CALCULATED.

PROCESS FLOW DIAGRAM IS ACCURATE

Process FMEA

PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT

DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART?

Dimensional Results

PPAP Level 3 Unless MEI SDE directs "other"


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A.

B.

C.

D.

E.

F.

G.

11 R R S * R

A.

B.

C.

D.

E.

F.

12 R S S * R

A.

B.

13 R R S * R

A.

B.

C.

D.

E.

F.

G.

14 S S S * R

15 R R R * R

16 R S S * R

17 R R R * R18 R R S * R

19 R R S * R

A.

20 * * S * *

A.

B.

C.

D.

E.21 * * S * *

22 R R S * R

23 * * S * *

A.

B.

24 S S S S R

A.

B.

25 S S S S R

A.

26 * * S S R

A.

CAPABILITY STUDY RESULTS ARE SUBMITTED ON THE PRODUCT CHARACTERISTICS MATRIX

PPK's FOR ALL CHARACTERISTICS ARE GREATER THAN, OR EQUAL TO, 1.67.

IF NO, A WRITTEN CORRECTIVE ACTION STATEMENT, FOR EACH, IS INCLUDED AND CONTAINMENT, WHEN

FEASIBLE, IS 100% INSPECTION.

RAW DATA IS INCLUDED FOR EACH STUDY

(per MAGNA XXX)

STUDIES ARE CONDUCTED FOR ALL CRITICAL AND SIGNIFICANT CHARACTERISTICS (EXCEPT DIMENSIONS

WITH BONUS TOLERANCES). EACH STUDY MUST INCLUDE THE STUDY DATE.

TEN (10) MEASUREMENTS FOR BONUS TOLERANCE DIMENSIONS ARE INCLUDED or PER MAGNA SDE DIRECTION

WRITTEN CORRECTIVE ACTIONS ARE INCLUDED FOR GAGE R&R'S GREATER THAN 30%.

THREE (3) OPERATORS, THREE (3) TRIALS ARE UTILIZED.

FORMS ARE COMPLETELY FILLED OUT.

WAS THE PROCESS CAPABILITY CALCULATED MADE OFF PARTS MADE FOR PPAP SUBMISSION?

PROCESS AVERAGES MATCH FOR MULTIPLE CAVITIES, DIES AND TOOL PROCESSES.

Measurement Systems Analysis (Gage R&R)

STUDIES ARE INCLUDED (AND DATED) FOR GAGES USED TO MEASURE SIGNIFICANT AND CRITICAL DIMENSIONS.

GAGE R& R FORM IS USED FROM MEASUREMENT ANALYSIS HANDBOOK.

PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT

DOES CONTROL PLAN REFLECTS LAUNCH PRACTICE ITEMS?

DOES IT SHOW SAME REVISION LEVEL AS PFMEA?

CONTROL PLAN ADDRESSES ALL SIGNIFICANT AND CRITICAL DIMENSIONS.

Qualified Laboratory Documentation

CERTIFICATE OF ACCREDITATION IS FROM A NATIONALLY RECOGNIZED ORGANIZATION.

SCOPE OF ACCREDITATION IS INCLUDED.

Control Plan

Appearance Approval Report (As Appropriate)

Bulk Materials Requirement Checklist (As Appropriate)

Sample Product

Master Sample

CONTROL PLAN ADDRESSES THE ENTIRE PROCESS FROM RECEIPT OF MATERIAL TO SHIPPING PRODUCT.

CONTROL PLAN INCLUDES ANNUAL REVALIDATION REQUIREMENTS.

CRITICAL FEATURES IDENTIFIED ON THE PCM, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS, CRITICAL

PROCESS CONTROLS, ETC.) ARE INCLUDED IN THE PFMEA AND HAVE RPN CALCULATED.

Product Characteristic Matrix (per MAGNA XXX)

ALL SUB-TIER SUPPLIERS HAVE BEEN INCLUDED BASED ON SUPPLY CHAIN MAP.

ALL SIGNIFICANT AND CRITICAL DIMENSIONS ARE INCLUDED, AND FOLLOW BACK TO THE MANUFACTURING

PROCESS THAT PRODUCES THEM.

Checking Aids

Compliance with Customer Specific Requirements

DOCUMENT(S) DEMONSTRATING COMPLIANCE WITH ANY OEM SPECIFIC COMMUNICATED REQUIREMENTS.

Additional MAGNA SPECIFICPPAP Requirements

Packaging Plan and Sample Label (per MAGNA XXX)

RUN-AT-RATE or Capacity Verification per MAGNA SDE DIRECTION (per MAGNA XXX)

DOES THE SUPPLIER NEED TO INCREASE THEIR CAPACITY?

ARE BOTTLENECKS IDENTIFIED AND RESOLVED? ARE THERE ANY TOOLING CONSTRAINTS?

PFMEA RPN'S ARE INCLUDED FOR ALL INCLUDED DIMENSIONS.

CUSTOMER TOUCH POINTS AND CRITICAL PROCESS CONTROLLED DIMENSIONS ARE INCLUDED.

SAFE LAUNCH PLAN DOCUMENTS CONTROLS THROUGHOUT THE SUPPLY CHAIN UP TO MAGNA.

Evidence of ELV / IMDS Approval

APPLIES ONLY TO SUPPLIERS TO FOR WHICH THE COMMERCIAL SITUATION DOES NOT ALLOW

FOR FULL DISCLOSURE.

Critical process approval (Heat treat, plating)

ARE THERE ANY CRITICAL SECONDARY PROCESSED THAT REQUIRES USE OF A RECOMMENDED SUPPLIER OR AMAGNA AUDIT BEFORE THEY ARE USED?

Certification of Review** (per MAGNA XXX)

Sub - contractor PPAP status

IS THERE A PSW FOR EACH COMPONENT AND MATERIAL IDENTIFIED IN THE BOM AND OR PCM?

ARE THE PSW'S FULLY APPROVED? IF NOT, IS THERE A MAGNA DEVIATION/CONCESSION FOR EACH PSW NOT

FULLY APPROVED?


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Instructions: For the submission of each Part Number, please utilize the MEI PPAP Checklist and insert the appropriate

PPAP document into its respective folder within the Zip File Master. If a document is not relevant/required, submit

an insert that notes that that element is not applicable. Examples are often AARs and DFMEAs.

PPAP Submission Folder


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Function Functio

NameDept.

Tel.

Fax.

E-mail

Address/

Location

Name

Dept.

Tel.

Fax.

E-mail

Address/

Location

Name

Dept.

Tel.

Fax.

E-mail

Address/

Location

Name

Dept.

Tel.

Fax.

E-mail

Address/

Location

Name

Dept.Tel.

Fax.

E-mail

Address/

Location

Name

Dept.

Tel.

Fax.

E-mail

Address/

Location

Name

Dept.Tel.

Fax.

E-mail

Address/

Location

Chris Hempsall

Purchasing

810-603-4137

[email protected]

Project Management

MEI Receiving Plant

Quality

MEI Receiving Plant

Logistic & Packaging

MEI Engineering

MEI Purchasing

Program Buyer

Contact Information

MEI Purchasing

Commodity Buyer

MEI APQP: Contacts- APQP TEAM

MEI Supplier

Development

Engineering
mailto:[email protected]:[email protected]

APQP Workbook

Documents

Transcript of APQP Workbook