S-APQP

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					                                                          S-APQP-Revision-Level:
    Supplier Advanced Product Quality Planning (S-APQP)       Last Revision-Date:



                    Supplier Name:
                          Location:
                        Part Name:
                  Part Description:
            Autoliv Part No. / Rev.:
              Autoliv Drawing No.:

 Project Team (Supplier)
#    Name                              Function                                     Phone
1
2
3

 Project Team (Autoliv)
#    Name                              Function                                     Phone
1
2
3

 Pre-Production delivery schedule                                                   Date
1
2
3

 Review meetings Autoliv / Supplier                                                 Date
1
2
3
                                                                                             S-APQP-Revision-Level:
     Supplier Advanced Product Quality Planning (S-APQP)                                         Last Revision-Date:



Confirmation that current revision of the S-APQP plan reflects the current project status.

  Project Team Leader                                              Supplier Signature                                  Date




Commitment to launch and complete the project according to the S-APQP planning.

  Management representative                                        Supplier Signature                                  Date




  Notes
                                                                                                                        S-APQP-Revision-Level:
      Supplier Advanced Product Quality Planning (S-APQP)                                                                   Last Revision-Date:



                                                                                                                                         Actual
                                                           Planned       Planned               Ready Status               Actual                      Follow-up / Comments /
# Activity                               Supplier Resp.                                                                                Completion-
                                                          Start-Date     Due Date                                       Start-Date                          References
                                                          (YYYY-MM-DD)   (YYYY-MM-DD)                                   (YYYY-MM-DD)      Date
                                                                                        20% 40% 60% 80% 100%   Status                  (YYYY-MM-DD)
                     Red                      Yellow        Green        Completed
1 Project Team
2 Feasibility Study and Action Plan
  completed
3 Contract Review
4 Serial Order and Drawings /
  Specification release
5 Prototype delivery schedule
6 Sub-supplier (material and sub-
  components) APQP and assessment

7 Design-FMEA (only if design
  responsible)
8 Special characteristics
9 Substance review
10 Reliability / Quality prediction
11 Software validation plan
12 Material / Performance validation
   plan
13 Design Verification (only if design
   responsible)
14 Lot Traceability Plan
15 Process flowchart
16 Process FMEA
17 Control Plan
      Supplier Advanced Product Quality Planning (S-APQP)



# Activity


                     Red
1 Project Team
2 Feasibility Study and Action Plan
  completed
3 Contract Review
4 Serial Order and Drawings /
  Specification release
5 Prototype delivery schedule
6 Sub-supplier (material and sub-
  components) APQP and assessment

7 Design-FMEA (only if design
  responsible)
8 Special characteristics
9 Substance review
10 Reliability / Quality prediction
11 Software validation plan
12 Material / Performance validation
   plan
13 Design Verification (only if design
   responsible)
14 Lot Traceability Plan
15 Process flowchart
16 Process FMEA
17 Control Plan
                                                                                                                       S-APQP-Revision-Level:
     Supplier Advanced Product Quality Planning (S-APQP)                                                                   Last Revision-Date:



                                                                                                                                        Actual
                                                          Planned       Planned               Ready Status               Actual                      Follow-up / Comments /
# Activity                              Supplier Resp.                                                                                Completion-
                                                         Start-Date     Due Date                                       Start-Date                          References
                                                         (YYYY-MM-DD)   (YYYY-MM-DD)                                   (YYYY-MM-DD)      Date
                                                                                       20% 40% 60% 80% 100%   Status                  (YYYY-MM-DD)
                    Red                      Yellow        Green        Completed
18 AS2 Process Audit
19 Facilities and Process Equipment
20 Measuring and Control Equipment
21 Production tooling procurement
22 Work instructions / Inspection
   instructions
23 Training
24 Material Handling and Packaging
   Instructions
25 Maintenance Plan
26 Engineering Sample Approval
27 Appearance approval reports (AAR)
28 Sub-supplier PPAP
29 Special Processes
30 First-Production-Trial-Run and
   Corrective Actions
31 PPAP-Production-Trial-Run and
   PPAP-Package Preparation
32 Measurement System
33 Initial Capability Studies and SPC
   Plan
34 Product / Production Validation
     Supplier Advanced Product Quality Planning (S-APQP)



# Activity


                    Red
18 AS2 Process Audit
19 Facilities and Process Equipment
20 Measuring and Control Equipment
21 Production tooling procurement
22 Work instructions / Inspection
   instructions
23 Training
24 Material Handling and Packaging
   Instructions
25 Maintenance Plan
26 Engineering Sample Approval
27 Appearance approval reports (AAR)
28 Sub-supplier PPAP
29 Special Processes
30 First-Production-Trial-Run and
   Corrective Actions
31 PPAP-Production-Trial-Run and
   PPAP-Package Preparation
32 Measurement System
33 Initial Capability Studies and SPC
   Plan
34 Product / Production Validation
                                                                                                                 S-APQP-Revision-Level:
     Supplier Advanced Product Quality Planning (S-APQP)                                                             Last Revision-Date:



                                                                                                                                  Actual
                                                    Planned       Planned               Ready Status               Actual                      Follow-up / Comments /
# Activity                        Supplier Resp.                                                                                Completion-
                                                   Start-Date     Due Date                                       Start-Date                          References
                                                   (YYYY-MM-DD)   (YYYY-MM-DD)                                   (YYYY-MM-DD)      Date
                                                                                 20% 40% 60% 80% 100%   Status                  (YYYY-MM-DD)
                    Red                Yellow        Green        Completed
35 PPAP Submission
36 Run at Rate
37 SOP
38 Early Production containment
39 Design Reviews
     Supplier Advanced Product Quality Planning (S-APQP)



# Activity


                    Red
35 PPAP Submission
36 Run at Rate
37 SOP
38 Early Production containment
39 Design Reviews
1 Project Team
Assignment of responsibility to a supplier cross functional team and a team leader with full commitment
and support from supplier upper management.

2 Feasibility Study
The supplier project team shall perform a feasibility study to verify that all technical data, qualities and
functions are correctly stated and that it is possible to achieve them.
The supplier reports the results by using the Team Feasibility Commitment template (TFC-template) and
by listing any concerns on the "Specification and Drawing Concern Sheet". Any open items from the
"Specification and Drawing Concern Sheet" must be closed before the activity "Feasibility Study" is
defined as completed.

3 Contract Review
This review is held with the appropriate participation from Autoliv and the supplier. The aim is to review
and confirm all aspects in the contract between Autoliv and the supplier ( i e technical, commercial,
logistic, quality , timing, results from the feasibility study etc ) The template "Contract Review" shall be
used to document the agreements.

4 Serial/Tool order and Drawings / Specifications Release
The date for serial/tool order shall be defined and included in the S-APQP.
If the supplier is responsible for the design, date for release of final and complete product documentation
e.g. bill of material, component/assembly drawings and specifications shall be defined and included in S-
APQP.
If Autoliv is responsible for the design, a date for final documents (design freeze) and submission of
documents shall be defined. The supplier shall proactively request missing documentation. If missing
documentation compromises the project timeline the supplier shall inform the responsible buyer
immediately in writing.

5 Prototype Delivery Schedule
A plan shall be established for Prototypes including delivery dates, volumes, technical status (i e pre-
serial parts), material planning and definition of tools and production equipment.

6 Sub supplier APQP
The material or components that shall be used must have APQP and PPAP activities planned. These
must show that the materials are approved within the timeframe of the project and that used sub
suppliers were selected according to defined supplier requirements. Even if the sub supplier is selected
by Autoliv, the supplier is responsible for sub supplier APQP and performance.


7 Design FMEA
DFMEA's shall be done according to the guidelines in the AIAG Failure Mode and Effects Analysis
handbook.
If the supplier is not Design responsible, the DFMEA is completed by Autoliv. All pertinent information
from the D-FMEA shall be communicated, understood and agreed upon between supplier and Autoliv to
ensure full consistency between the D-FMEA and the P-FMEA. The supplier is responsible to assure that
all necessary D-FMEA information is received in order to develop the P-FMEA. (See also item 15. P-
FMEA below).
If the supplier is responsible for the design, a D-FMEA shall be completed and submitted to Autoliv
together with an action plan for acceptance by Autoliv.
D-FMEA shall be planned so that necessary actions can be implemented before the design phase of the
project is closed. (Ref.: AS104 D-FMEA (Potential Failure Mode and Effects Analysis in Design))


8 Special Characteristics
The process to identify, control and verify Special Characteristics during development, PPAP and serial
production shall be performed according to AS52. The CC/SC's shall be documented in the CC/SC list
(AS 52 ). All identified CC/SC's carried through to all relevant documents (i.e. drawings , control plan,
work instructions etc.)
If Autoliv is responsible for the design, the supplier shall receive information about CC/SC's from Autoliv.
The supplier shall as a result from his P-FMEA process create a CC/SC list including the CC/SC's
identified by Autoliv and by the supplier. The results from this process shall also be used to define those
characteristics or process parameters which shall be controlled by SPC, 100% detection of defects or
Poke-Yoke during serial production. The supplier shall submit results from his ongoing control and
verification of CC/SC's as directed by the using Autoliv facility.

Further, if nothing else is specified, the below mentioned characteristics must be verified on finished
components after all manufacturing process steps have been completed, prior to shipping of a
manufacturing lot/batch to Autoliv. Method of testing to be agreed with Autoliv. The verification shall be
included in the Control Plan.

Strength
When strength is a requirement, a minimum of three pieces per lot shall be tested, with a minimum of
one per cavity. The failure strength and mode shall be noted on the certification/lab report.


Hydrogen embrittlement
When components are subject to hydrogen embrittlement, a minimum of five pieces per lot shall be
tested.

Hardness
When hardness is a requirement, a minimum of three pieces per lot shall be tested.


9 Material and Substance Review
The supplier shall, independent of whether Autoliv or the supplier makes the material selection, review
the composition of each material. The materials shall be declared by the supplier through IMDS,
according to the requirements and guidelines defined by the AS5, and approved by Autoliv. In the case
of supplier designed or chosen materials, the supplier shall make sure the defined material conforms to
the AS5. Materials, components and products containing substances classified as forbidden must not be
used. If needed due to safety or other requirements, and no other alternatives exist the supplier shall
notify Autoliv immediately, which will initiate a deviation process. Any deviation must ultimately be
acknowledged by the vehicle manufacturer and approved centrally by Autoliv to become effective. (Ref.
AS 5)


10 Reliability / Quality Prediction
If specified by Autoliv, the supplier shall evaluate design and process and define estimated quality level
and reliability level .
Specific requirements for semiconductors and electronic components
It is required to calculate MTTF/FIT. Actions shall be established so defined requirements can be
assured. This can be done by e.g. design evaluation, control plan evaluation, burn in test.
0 km failure rate shall be calculated in PPM. Calculations and action plans shall be reported and agreed
by Autoliv.

11 Software Validation Plan
If the product includes software developed by the supplier, validation plans shall be reported to and
agreed by Autoliv.

12 Material / Performance Test Planning
Validation plans for all material tests and performance qualifications shall be established and resources
provided (equipment, personnel and laboratory) Autoliv will specify the qualification testing.

If the supplier has the design responsibility, Design Validation shall be planned. Final product and
process validation shall be realized by using serial status products.
The Process Flow Diagram shall include all processes from receiving, handling, manufacturing, final
inspection, final product audit and dock-audit.

13 Design Verification
If the supplier is responsible for the design, the chosen design shall be tested and evaluated to assure
that requirements and specifications are fulfilled. The verification shall be performed before the design
phase is completed so corrections can be implemented in the design. Components and material shall be
according to the drawing / specification

14 Lot Traceability Plan
The supplier has to establish a plan to define how all raw material, components, sub-components, and
production processes are traceable to the manufacturing lot/batch number or individual serial number.
The requirements also apply as appropriate to any sub-contractor. (Lot/batch size is defined in ASM-
Quality Requirements -"General")
A flow chart describing the traceability and documentation procedure shall be established.
(Ref.: AS 4)

15 Process Flow Diagram
The production process shall be planned and reported on a flow chart (including a lay-out) where all
supplier, sub-supplier and transportation operations / processes are described. All operations shall be
marked and correspond to P-FMEA and Control plan
The Process Flow Diagram shall include all processes from receiving, handling, manufacturing, final
inspection, final product audit and dock-audit.

16 Process-FMEA
P-FMEA´s shall be done according to the guidelines in the AIAG Failure Mode and Effects Analysis
handbook.
P-FMEA shall be carried out on the basis of the input from the D-FMEA , after a production layout and a
process flow chart have been produced. The P-FMEA analysis performed by the supplier shall be
reviewed with Autoliv to ensure that the D-FMEA and the P-FMEA are consistent including CC/SC's,
failure effect , severity ratings, etc.
Knowledge of the product , production and inspection equipment capability shall always be considered.
(Ref.: AS105)

17 Control Plans
The control plan shall be completed following the AIAG APQP/Control Plan manual and ISO/TS 16949. It
shall be completed in three stages: Prototype, Pre-Launch (PV) and Production.
It shall be created on the basis of the P-FMEA and the Process Flow Diagram . All control operations
shall be numbered and correspond with P-FMEA and Process Flow Diagram . CC/SC shall be marked
and identified. Autoliv may require additional controls - i.e. inspections that must be adhered to.


18 AS 2 Process Audit
If requested by Autoliv, an AS 2 Process Audit specific to the project will be performed by Autoliv

19 Facilities and Process Equipment
The supplier shall review and evaluate the defined production site, available and planned additional
production equipment, facilities and capacity. The activity includes specification, procurement and
qualification of facilities and equipment to be used for manufacturing of the product.


20 Measuring and Test Equipment
The supplier shall review and evaluate the defined measuring and test equipment (available and planned
) and its capacity.
The activity includes specification, procurement and validation of measuring and test equipment to be
used for manufacturing of the product.

21 Production Tooling Procurement
A plan (incl. timing) shall be established for production tools and product specific control instruments.
The plan must include timing regarding preparation of tooling drawings/specifications, manufacturing and
qualification of the tooling.
Identified and defined tools and production equipment that shall be used for serial manufacturing shall be
available at the time for the Production Trials and Product/Process Validation

22 Work Instructions and Inspection Instructions
Work, inspection, test and process instructions shall be defined describing manufacturing process
procedures and inspection/testing procedures, responsibilities and actions in case of non conformities.


23 Training
The supplier shall conduct a review of personnel to identify necessary competence and education . The
result shall be presented in the form of a training plan/procedure, where the following has been identified:
the required training, what is to be covered, who is doing the training, when it has to be done and
confirmation that it has been carried out. All the required training and product knowledge shall be
completed before the Run at Rate.

24 Material Handling and Packaging Instructions
The supplier shall complete an analysis of all handling and labeling which the product is subject to (from
delivery of raw materials, through manufacturing to delivery to Autoliv) with the aim of ensuring that the
materials/products are identified, handled, stored, packed and transported in such a manner that a
change or deterioration is prevented. A plan for material handling shall include the product flow,
replenishment system, and packaging (Ref.: ASM Logistics Requirements)
25 Maintenance Plan
The supplier shall conduct and review a maintenance plan for production equipment. The documented
plan shall be in accordance with requirements defined in ISO/TS 16949

26 Engineering Sample Approval (ESA)
If samples are evaluated by Autoliv e.g. form, fit or function, the approval and comments shall be
documented. Samples shall be delivered to Autoliv for approval (Ref.: AIAG PPAP Manual - ESA form)


27 Appearance Approval Report (AAR)
The supplier shall plan for evaluation of parts with visible surfaces, structure and colour. Samples and
measuring results shall be reported on AAR and submitted to Autoliv for approval. ( Ref.: AIAG PPAP
Manual -AAR template)

28 Sub supplier PPAP
The supplier shall ensure that all components and materials to be used for serial manufacturing are
PPAP approved or certified to raw material specification. Only approved material shall be used for
manufacturing of PPAP parts and for product/process validation.

29 Special processes
Special processes are processes where following inspection and testing cannot totally verify the results.
Examples are: heat treatment, welding, surface treatment, gluing, soldering etc. Special processes shall
be controlled and documented to assure the output meets specifications.
All required fixed parameters are to be defined as process instructions in the control plan.
For heat treatment processes, acceptable results from an Autoliv heat treatment audit is required before
PPAP can be approved. (Ref AS 069 " Heat treatment requirements")

30 First Production Trial Run and Corrective Actions
The supplier shall schedule the First Production Trial Run to ensure adequate time for corrective actions
before the PPAP Production Trial Run. Requirements and documentation shall be as defined in "
Production Trial Run Standard ". (Reference ASM Product Life Cycle Step 7 "Production Trial Runs "
and the " Production Trial Run Standard ".)

31 PPAP Production Trial Run and PPAP Package Preparation
Date for PPAP Production Trial Run as well as the time required for PPAP preparation and submission
shall be scheduled and included in S-APQP. (Ref.: Reference ASM Product Life Cycle Step 8 " PPAP
and Run at Rate " and " Production Trial Run Standard ")

32 Measurement System
The supplier shall conduct an evaluation of all test and measuring methods that are planned for serial
production. Gauge R&R values for measuring method, including operator, material and environmental
variations shall be documented in the PPAP. Special attention shall be considered for verification of
measuring method regarding CC / SC. (Reference: AIAG Manual "MSA Reference Manual")


33 Initial Capability Studies
The supplier shall perform an initial capability study (Ppk) to identify and verify the manufacturing
process capability.
(Reference : "Production Trial Run Standard", AS 52, AIAG Manual "PPAP and "SPC" )
34 Product / Production Validation
The supplier shall perform final tests and qualifications for product / process validation with products
manufactured in the defined production process, under normal serial conditions and using PPAP
approved or certified materials to ensure that product requirement, functions and specifications can be
validated.

35 PPAP Submission
The supplier shall plan for preparation, submission and approval of PPAP documentation . In case
submission date will be changed, supplier must inform Autoliv immediately using the S-APQP form. In
case supplier will request an interim approval, the Interim Recovery Worksheet and any additional
documents as defined by the using facility shall be submitted before PPAP. Reporting shall be done in
accordance with the AIAG Production Part Approval Process manual ( Reference AIAG PPAP Manual
and ASM - Quality Requirements -"PPAP")

36 Run at Rate
Date for Run at Rate shall be scheduled and included in S-APQP.
Autoliv shall always be informed about time for realisation so the opportunity is given to attend.
(Reference : ASM Product Life Cycle Step 7 "Production Trial Runs and 8 " PPAP and Run at Rate " and
" Production Trial Run Standard ")

37 Start of Production (SOP)
Date for the supplier Start of Production shall be included in S-APQP and aligned with the Autoliv SOP
date.

38 Early Production Containment
The content of the enhanced control and inspection activities shall be defined ,planned. and agreed with
Autoliv. Before termination of the actual activities, the supplier must get an approval from Autoliv.

(Reference : AS 412 " Interim Inspection Plan "and ASM Product Life Cycle Step 10 "Performance
Review / APQP Closure")

39 Design Reviews
Supplier internal design review meeting schedule to be included. (Design review activities are defined in
the AIAG manual "APQP".)
1. When you open this template, please confirm the Microsoft Excel messagebox with 'Activate macros'.
   Otherwise the template doesn't work correctly.

2. After successful confirmation of the macro activation you will be able to select a Autoliv location. The address
and
   optional the phone/fax number will be placed at the left side of the footlines (only sheet General and
   Activity Planning). Double click at one of the listed Autoliv location or confirm with OK to prepare the footlines.
   Confirm with Cancel to ignore the footline definition.

3. At the bottom of the Excel application window is placed a specific toolbar, called 'S-APQP.
   This toolbar has the following three functionalities:
   a) Insert Line (Sheet General)
   b) Delete Line (Sheet General)
   c) Rename Actvity (only for users with the status Administrator; sheet Activity Planning)

4. Use the function 'Insert Line' to add an additional line at the section 'Project Team (Supplier)',
   'Project Team (Autoliv)', 'Pre-Production delivery schedule', 'Review meetings Autoliv/Supplier' and 'Notes'.
   Therefore select one of the lines of the section above the new one should be inserted and
   confirm the function 'Insert Line'.

5. Use the function 'Delete Line' to delete a line of the section 'Project Team (Supplier)',
   'Project Team (Autoliv)', 'Pre-Production delivery schedule', 'Review meetings Autoliv/Supplier' and 'Notes'.
   Therefore select the line of the section which has to be deleted and confirm the function 'Delete Line'.
   Minimum one line for each section is required.

6. Use the function 'Rename Activity' to change the name of the selected activity.
   Therefore select the activity which has to be changed and confirm the function 'Rename Activity'.
   Type in the Administrator password and confirm with OK. If the password is correct, please type in the new
name of
   the activity an confirm with OK. Otherwise the process will be canceled.

7. The planning of the activities do not function for the past. For example: Current year is 2004, therefore no
activities
   dated in 2003 are possible.

8. The strong yellow colored Activities are items of the critical path. For this activities only Administrators have
the

9. Column Supplier Resp.:
   Please use the pulldown-list to select one of the listed team members.
   In some cases it's allowed to type in a name which isn't listed at the Supplier-Project-Team.

10. Columns 20%, 40%, 60%, 80% or 100%:
  Double click at the related status column (20%, 40%, 60%, 80%, 100%) of the Activity row to change the
  Ready Status. If the status is 20%, then double-click at 20% once again to set the Ready Status to 0%.

11. Column Status:
  Please use the pulldown-list to select one of the listed status Empty, Red, Yellow or Green.
  Use the first item 'Empty' to clear the status.
12. Please take care, that for the first time you have to type in the Planned-Start-Date and Planned-Due-Date
and for
    the second time the Actual-Start-Date and Actual-Completion-Date. Otherwise a wrong message will be
displayed.

13. Please use the date format 'YYYY-MM-DD' as titled in the header or all the other valid date formats, e.g.
    'dd.mm.yy', 'dd.mm.yyyy', 'mm/dd/yy', ...
    Otherwise a wrong message will be displayed.

14. The Planned time frame will be highlighted as a bordered frame.

15. The Actual time frame will be highlighted with a blue colored background.

16. Maximum 4 calendar years are available for the project planning.

IMPORTANT FOR PRINTING:
Please use the view 'Page Break Preview' from menu 'View' to set the horizontal and vertical page breaks
manually.
The blue continous drawed lines are manual page breaks, blue dashed lines are automatical page breaks.
Move the page breaks to the place for optimal printout.
Move the vertical page breaks that the whole calendar year is visible at the width of one page.

Please take care that you have to select any cell of the sheet General or Activity Planning after you have
printed the document or if you go back from preview to normal view. This step is neccessary to reset

				
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posted:10/26/2011
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