4 Phases of APQP by jyJmfaO1

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									        Supplier APQP: Four Phases




Date: 14 May, 2008
                                                                        Process Owner/Department:
Rev. A                               Magna Electronics APQP Woorkbook
                                                                                    Chris Hempsall
                                                                                      Approved by:
                                                                            Justin Reaume / Pur Dir
Supplier APQP: Table of Contents
 Cover                      Shows the 4 APQP Phases and the activities that occur within them.

 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 Feasibility       In accordance with The Automotive Industry Action Group (AIAG) and OE specific requirements, the supplier's team
 Statement                  feasibility 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.

 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.

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


 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. The
                            additional columns would either be used at the discretion of the SDE or based on circumstances that require additional
                            reviews.


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

 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).


 Product                    The PCM is used initially to define and determine appropriate controls for special characteristics, other process critical
 Characteristics Matrix -   features and customer touch points. This tab is used to define the process at MEI's direct supplier. Throughout the APQP
 Tier II                    phase of launch this form is used as the Pre-Launch Control Plan and also forms the basis for Safe Launch Planning.



 Product                    The use of this tab is identical to the functionality define above, with the exception that this is used to document the
 Characteristics Matrix -   remaining supply chain's, below the Tier II supplier, impact on the critical features.
 Sub-Supplier



 PCM - Weekly QOS           Format to be used for a weekly summary of the inspection results from the Safe Launch Plan. This information will be
 Report                     used as part of the decision making process for the removal of the Safe Launch Controls.



 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.


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


 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.




                                                             Magna Electronics APQP Workbook
                                                                                                                                   Process Owner/Department:
 Date: 14 May, 2008                                                                                                                           Chris Hempsall
 Revision: A                                                                                                                                    Approved by:
                                                                                                                                              Justin Reaume
                                                        Supplier Design Review Sign Off

   Part Name:                                                  Part No.:                                                     Date: ________________
                                                               Rev. No.:
          Review Considerations:

          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.


             YES          NO                                                           Considerations
                                   Is the product adequately defined (application requirements, etc.) to enable feasibility evaluation ?
                                   Can Engineering Performance Specifications be met as written?
                                   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?
                                   Can product be manufactured without incurring any unusual:
                                                           l Costs for capital equipment?
                                                           l Costs for tooling?
                                                           l Alternative manufacturing methods?
                                   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:
                                                           l Are the processes in control and stable?
                                                           l 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?
          Conclusion:
                       Feasible                                > Product can be produced as specified with no revisions.
                       Feasible (Conditional)                  > Changes recommended (see issues list below).
                       Not Feasible                            > Design revision required to produce product within the specified requirements.


Issue #      Open        Close                      Issues / Comments / Risks                               Corrective Actions / Resolution Plan




Sign-Offs:
Magna Electronics                                                                           Supplier _____________________________
Name:                                                                                       Name:
Title:                                                                                      Title:
Signature:                                                                                  Signature:
Date:                                                                                       Date:

Name:                                                                                       Name:
Title:                                                                                      Title:
Signature:                                                                                  Signature:
Date:                                                                                       Date:
Supplier APQP: Four Phase Time Line (EXAMPLE)
The Magna Electronics Supplier Advanced Product Quality Planning (APQP) process consists of 4 Phases. Essential to this process are 12 Key Supplier Metrics (KSM). These metrics are established in the initial phase and then updated and
reviewed during each of the following phases. The time line below illustrates the relationship between the 4 Phases, their deliverables and the Global Development & Product Introduction Management process.

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 of the priority ranking assigned components/materials requiring submission of
a PPAP package.

                                                                                                                                            Year 1                                                                                                                            Year 2
    PHASE
    APQP




                                               OUTPUT




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                        1.1    Design FMEA
    Supplier Kick-Off




                        1.2    Preliminary Capacity Study reviewed
                        1.3    Manufacturing Feasibility reviewed
                        1.4    Component Design Review
           1.




                               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
 Product/Production




                        2.3    Preliminary PFMEA Review
     Realization




                        2.4    Preliminary Control Plan Review
                        2.5    Tooling
         2.




                        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
    Pre-PPAP




                        3.4    Supplier Ramp Plan
        3.




                        3.5    Plant Readiness Review
                        3.6    Launch Readiness Audit
                        3.7    Appearance Approval Process (when applicable)
                        3.8    Key Supplier Metrics reviewed
Validation &




                        4.1    PPAP
 Product/
 Process




                        4.2    Launch Readiness Audit
     4.




                        4.3    Run at Rate
                        4.4    Key Supplier Metrics reviewed
                        4.5    OK to Launch Sign-Off
                         5.1
 Requirements




                         5.2
                         5.3
    Other
      5.




                         5.4
                         5.5
                         5.6
                         5.7


                                                                                    KEY:                X Planned start                               O         Planned completion                                +         Actual start                       >         Actual end

                                                                                                                                      Magna Electronics APQP Workbook
Supplier APQP: Blank Time Line
                                                                                                                                           Year 1                                                                                                                            Year 2
    PHASE
    APQP




                                               OUTPUT




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                        1.1    Design FMEA
    Supplier Kick-Off




                        1.2    Preliminary Capacity Study reviewed
                        1.3    Manufacturing Feasibility reviewed
                        1.4    Component Design Review
           1.




                               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
 Product/Production




                        2.3    Preliminary PFMEA Review
     Realization




                        2.4    Preliminary Control Plan Review
                        2.5    Tooling
         2.




                        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
    Pre-PPAP




                        3.4    Supplier Ramp Plan
        3.




                        3.5    Plant Readiness Review
                        3.6    Launch Readiness Audit
                        3.7    Appearance Approval Process (when applicable)
                        3.8    Key Supplier Metrics reviewed
Validation &




                        4.1    PPAP
 Product/
 Process




                        4.2    Launch Readiness Audit
     4.




                        4.3    Run at Rate
                        4.4    Key Supplier Metrics reviewed
                        4.5    OK to Launch Sign-Off
                         5.1
 Requirements




                         5.2
                         5.3
    Other
      5.




                         5.4
                         5.5
                         5.6
                         5.7


                                                                                    KEY:                X Planned start                              O         Planned completion                                +         Actual start                       >         Actual end
APQP: Key Supplier Metrics Operational Definitions
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



          Metric                           Definition                                     Goal                                       Results

APQP Readiness             Data is derived from the 'APQP Progress                                                  Enter the number of GREEN elements at
                           Report'. This metric tracks the                                                          the time of the report.
                           percentage of GREEN elements
                           compared to the total number of
                           elements being tracked.
                                                                       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.



Process Instructions       Total number of set-up, manufacturing                                                    Enter number of completed process
                           and inspection instructions needed.                                                      instructions at the time of the review.
                                                                       Enter total number of process instructions
                                                                       needed for serial production.


First time Capability      Percentage of good parts to the total                                                    Enter, as a decimal number, the ratio of
                           number of parts produced during the Run                                                  total parts produced to good parts from
                           at Rate.                                                                                 the trial run.
                                                                       Enter the number '1,' which represents the
                                                                       production of 100% good, or usable, parts.

Process Efficiency         Measured in available capacity.                                                          The amount of available capacity at the
                           Expectation for open capacity is 15%                                                     time of the review. Enter result as a
                           minimum. This is achieved by dividing                                                    decimal number.
                           Takt time into cycle time and subtracting   The minimum amount of available capacity
                           the result from 1.                          should be 15% (85% utilization). Enter
                                                                       0.15
Process Capability         The number of designated                                                                 Enter the number of characteristics, with
                           characteristics with a Ppk > 1.67.                                                       a Ppk > 1.67, at the time of the review.


                                                                       Enter the total number of designated
                                                                       characteristics on the drawing.
Test Achievement           Total number of performance and                                                          This is the total number of samples that
                           materials tests that need to be conducted                                                passed all of the required testing at the
                           to meet the specifications shown on the                                                  time of the review.
                           drawing. This number is a combination The should represent the total number of
                           of the number of unique tests multiplied individual tests required times the number
                           by the number of samples required for     of samples, for each test, that is required.
                           the test.
APQP: Key Supplier Metrics Operational Definitions
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



         Metric                           Definition                                    Goal                                      Results

APQP Readiness           This is derived from the level of
Process Implementation - Data metric assessesthe 'APQP Progress                                                   Enter the appropriate stage of process
% Completed              Report'. This metric tracks the
                         implementation of the full production                                                    implementation in regard to
                         percentage of GREEN elements not
                         intent process. Processes that are                                                       manufacturing for serial production.
                         compared to the total number of
                         fully implemented at the Start-of-                                                       1. Prototype process is implemented; No
                         elements being tracked.
                         Production require a deviation, or                                                       released deviation of concession; No
                         concession, to allow shipment. This                                                      containment plan.
                         document needs to clearly define the                                                     2. Interim process implemented, with
                         state of the process implementation,                                                     partial production intent process; No
                         provide a time line for completing the                                                   released deviation or concession; No
                         implementation, list any non-conformities                                                containment plan.
                         to the drawing and/or specifications, and                                                3. Prototype or partially implemented
                         a containment plan to keep those non-                                                    process; Released deviation or
                         conformances from reaching MEI.                                                          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.

Launch Readiness Audit     A comprehensive audit tool's score,                                                    The score achieved on the Launch
                           which assesses a process's state of                                                    Readiness Audit. Enter data as a
                           preparation to meet serial production                                                  decimal number.
                           requirements.
                                                                     The minimum goal for full release for
                                                                     production is 90%. Goal is 100% and
                                                                     entered as "1".
Sub-Component PPAP         Number PPAPs approved for the                                                          The number of approved sub-component
Approvals                  purchased sub-components and                                                           and material PPAPs at the time of the
                           materials that makes up the final shipped                                              report.
                           component/material, and that do not have
                           any deviations, waivers, and/or           The number of approved sub-component
                           concessions granted by any tier below     and materials making up the shipped
                           MEI.                                      component/material.

PPAP Package               Number of PPAP submission package                                                      The number of elements (or documents)
Completion                 elements completed compared to                                                         completed for the PPAP package at the
                           required number.                                                                       time of the review.

                                                                     The total number of required elements, or
                                                                     documents, required to be submitted.
APQP: Key Supplier Metrics Operational Definitions
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



         Metric                            Definition                                       Goal                                     Results

APQP Readiness
Supplier Ramp Plan         This is derived from the 'APQP Progress
                           Data element evaluates a supplier's ability                                               Enter the number corresponding to the
                           to meet This metric tracks volumes.
                           Report'. ramp-up timing andthe                                                            completed stage from the list below.
                           percentage of GREEN elements                                                              1. Has not received any production
                           compared to the total number of                                                           releases from using plant(s).
                           elements being tracked.                                                                   2. Is receiving production releases from
                                                                                                                     the using plant(s), but no production
                                                                                                                     schedule or plan documented to meet
                                                                                                                     those volumes or has 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 and
                                                                                                                     has 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.
Safe Launch Plan (PCM)     Completion of the PCM is noted by                                                         Enter number of completed stage at time
Deployment                 Operations, i.e., plant, approval of the                                                  of review.
                           Safe Launch Plan portion of the form.         Enter the number '5' representing the
                                                                         completion of the PCM, less the exit from
                           Stages of completion are:                     the Safe Launch Plan. This applies to
                           1. MEI's supplier has completed the           situations where the PPAP will be
                           form, less SLP.                               submitted in a span of time from before
                           2. MEI's supplier has completed their         SOP to 30 days after SOP.
                           sub-supplier form, less SLP.
                           3. Supplier section completed, including Enter the number '6' for situations where
                           SLP.                                     the SLP exit is required for closing APQP.
                           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 APQP: Key Supplier Metrics Report

      Supplier Name:                                                                             Supplier Location:                                         Supplier Code:

      Part Number:                                                                               Part Name:                                                 Revision Level:

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


Primary Indicator:
                                                                                                                                     Goal                                     Results

                                                 Production Preparation Influencing Factors                                         Target

                                                              Number of 'Progress Report' elements with Green status
                             1. APQP Readiness
                                                              Total number of elements from 'Progress Report'
                                                              Total number of instructions completed
                             2. Process Instructions
                                                              Total number of instructions needed.
        MANUFACTURABILITY




                                                              Results from Run at Rate
                             3. First Time Capability
                                                              Ideal % of good parts

  K                                                           Available capacity based on % of cycle time to Takt time
  E                                                           achieved
                             4. Process Efficiency
  Y                                                           Maximum acceptable % of available capacity base on %cycle
                                                              time to Takt time
 M                                                            Number of capable designated characteristics features
 E                           5. Process Capability
                                                              Total number of designated characteristics features
 A
 S                                                            Number of tests passed
                             6. Test Achievement
 U                                                            % of total tests
 R
                             7. Process Implementation -      High volume process or Interim Process with Concession
 E
                             % Completed                      Production volumes provided off production intent process               5
 A
 B                                                            Score achieved during event
 L                           8. Launch Readiness Audit
        PPAP




                                                              Goal is 100%.
 E
                             9. Sub-Component PPAP            Number of sub-components and materials PPAP approved
 S
                             Approvals                        Total number of purchased sub-components/materials

                             10. PPAP Package                 Number of PPAP required documents completed
                             Completion                       Number of PPAP required documents required
                                                              State of completed supplier ramp plan
                             11. Supplier Ramp Plan
                                                              Ramp planned completed and shipping to releases                         5
        DLN




                             12. Safe Launch Plan (PCM)       Enter completed stage of PCM (see comments)
                             Deployment                       Complete Stage 5 by SOP                                                 5

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



SUPPLIER SIGN-OFF (MANAGER LEVEL)

                            Function                   Project Leader       Purch/Sales          Production Control       Quality            Engineering            Design              Manufacturing

                      Name (print)
                            Signature



MEI SIGN-0FF
                                                   SDE                            Name (print)                                      Signature
      MEI Internal Use only                        Commodity Mgr/Buyer            Name (print)                                      Signature
                                                   SQA                            Name (print)                                      Signature
Supplier APQP: Supply Chain Map - Example

        TIER 4              TIER 3                TIER 2
       SUPPLIER            SUPPLIER              SUPPLIER




                      Kojak Heat Treat
                      Benton Harbor, MI
                       Harden & Draw
                                            Fine Fasteners, Inc.
                                             Benton Harbor, MI
                                             M8x20 Weld Stud
                                                59039813A
                                               Cold Forming
    Anaconda Steel     White & Jones
       Erie, PA          Jackson, MI
      C1038 Rod          C1038 Rod
                                                                                            3rd Party          CUSTOMER
       Steel Mill     Wire Draw, Anneal
                                                                                           Warehouse


                                                                   TIER 1 SUPPLIER                             Magna Electronics
                                                                                              Saf-Store
                                                                                                                  Holly, MI
                                                                                              Mesa, AZ
                       AAA Heat Treat                                                     Warehouse Services
                        Frederick, MD                               Precision Forming
                       Harden & Draw                                    Amarrillo, TX
                                               ABC Nut Co.          Airbag Reaction Can
                                                Summit, NJ               49019804A
                                             M8x15 Staking Nut      Stamping body, end
                                                59039812C              caps, brackets
                                               Cold Forming
     Pacific Steel    B&C Processing
    Los Angeles, CA    Georgetown, PA
                                                                                                               Magna Electronics
      C1024 Rod          C1024 Rod
                                                                                                                Monterrey, MX
       Steel Mill     Wire Draw, Anneal




                      Dynamic Chemical
                          Supplies           Zephyr Coatings
                          Tulsa, OK             Austin, TX
                       Coating materials,        E-Coat
                           solvents
Supplier APQP: Supply Chain Map
  Supplier:                       Part Number:               Date:                   Revision:

                                                           ME Receiving     OEM
     Tier V         Tier IV        Tier III      Tier II    Operation
                                                                                                 Tier
                                                                          Customer
Supplier APQP: Product Characteristic Matrix

                             Part Name:                                                                          Supplier Name:                                                                        Rel. Date:


            Part Number/ Revision:                                                                                        Location:                                                                    Rev. Date:


                  Project/ Program:                                                                          MEI Using Plant(s):




                                          MEI/ Supplier                                                        TIER II - Supplier Process Control                                                            Safe Launch Plan (SLP)
 #                                                                                                                                     Gauge
                                          Level/      DFMEA   PFMEA        PFMEA
     Design Characteristic                                                              RPN   Control Method/ Equipment                 R&R      Pp/ Ppk      Freq./Size   Control Method/ Equipment   Freq./Size   Reporting         Cpk/Cp   SLP Exit Criteria
                                          Class        Sev.    Occ.         Det.
                                                                                                                                       % Tol




                                                                                                                          Characteristic Review Approval

                                                   Name               Position/ Title                         Date                                Signature                                                    Additional Comments
MEI SDE
MEI Plant SQA
Supplier Representative

                                                                                                                            Safe Launch Exit Approvals

                                                   Name               Position/ Title                         Date                                Signature                                                    Additional Comments
MEI SDE
MEI Plant SQA
Supplier Representative
Supplier APQP: Product Characteristic Matrix (Sub-Supplier)

                             Part Name:                                                                               Supplier Name:                                                                          Rel. Date:


              Part Number/ Revision:                                                                                         Location:                                                                       Rev. Date:


                    Project/ Program:                                                                              MEI Using Plant(s):



                                              TRW/ Supplier                                                               Sub-Supplier Process Control                                                    Safe Launch Plan (SLP)
 #                                                                                                                                       Gauge
                                          Level/     DFMEA       PFMEA            PFMEA
     Design Characteristic                                                                     RPN   Control Method/ Equipment            R&R    Pp/ Ppk       Freq./Size   Control Method/ Equipment   Freq./Size         Reporting   Cpk/Cp   SLP Exit Criteria
                                          Class      Severity   Occurrence       Detection
                                                                                                                                         % Tol




                                                                                                                     Characteristic Review Approval
                                                   Name                      Position/ Title                       Date                            Signature                                                 Additional Comments
MEI SDE
MEI Plant SQA
Supplier Representative

                                                                                                                       Safe Launch Exit Approvals
                                                   Name                      Position/ Title                       Date                            Signature                                                 Additional Comments
MEI SDE
MEI Plant SQA
Supplier Representative
Safe Launch Plan: Weekly QOS Report

                                                                 Touch Point Incident & PPM Monitoring                                                                                                                                                                                             Pareto Failures By Process

                   70                                                                                                                                   30000                             12          11
                                                                                                                                                                                                                           10
                                                                                                                                                                                          10
                   60                                                                                                                                   25000                              8                                               7




                                                                                                                                                                               Incident
                                                                                                                                                                                                                                                          6
                                                                                                                                                                                           6                                                                               5                  5                  5
                   50                                                                                                                                                                                                                                                                                                                   4
                                                                                                                                                        20000                              4                                                                                                                                                            3                     3
                                                                                                                                                                                                                                                                                                                                                                                                 2                      2                   2
                   40
        Incident




                                                                                                                                                                                           2




                                                                                                                                                                PPM
                                                                                                                                                        15000                                    0                         0      0                   0       0                           0        0                                0       0                             0          0                              0           0                             00     00                          00     00                                  00       00                         00   00
                                                                                                                                                                                           0
                   30




                                                                                                                                                                                                                                                                                                                                                                                  contamination, Blistering, runs
                                                                                                                                                                                                                                                                                                                                            Brake cable hole position
                                                                                                                                                                                                                                                                Adjuster hole diameter
                                                                                                                                                                                                                                   Nut thread check




                                                                                                                                                                                                                                                                                                                                                                                                                             No Cracks on backplate (visual




                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        Dust ring gap to backplate check
                                                                                                                                                                                                                                                                                                   Wheel cylinder hole diameter




                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     Hold down pin diameter
                                                                                                                                                                                                                                                                                                                                                                                                                                                                     Brake cable hole diameter




                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                     Mounting holes position
                                                                                                                                                                                                  Abutment hole diameter
                                                                          Example




                                                                                                                                                                                                                                                                                                                                                                                     NO paint scratch and or
                                                                                                                                                        10000
                   20




                                                                                                                                                                                                                                                                                                                                                                                                                                  boundary sample)
                                                                                                                                                        5000
                   10

                    0                                                                                                                                   0
                        W14        W15       W16      W17     W18       W19   W20      W21       W22   W23   W24   W25   W26   W27   W28         W29

                                                                                     Incidents     PPM




                                                                                                              Total                   WEEK             W14            W15    W16                W17                             W18                       W19                             W20                                      W21                                  W22                 W23                              W24                                   W25                            W26                                       W27                                W28              W29
                                                                                                                71                   Incidents          65             0      1                   5
                                                                                                               9350                    QTY             2350           3500   3500
                                                                                                               7594                    PPM             27660            0     286              #VALUE!                         #VALUE!                #DIV/0!                            #DIV/0!                                  #DIV/0!            #DIV/0!                        #DIV/0!                                 #DIV/0!                            #DIV/0!                           #DIV/0!                                   #DIV/0!                      #DIV/0!      #DIV/0!
Fault
                                       Failure Mode                            Total                          Action                  Timing           W14            W15    W16                W17                             W18                       W19                             W20                                      W21                                  W22                 W23                              W24                                   W25                            W26                                       W27                                W28              W29
 No.
 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                                                                        3
 21           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
Supplier APQP: Open Issues - Corrective Action Plan
  Supplier Name:                                                              Component Manufacturing Location:                                           Supplier Code:

  MEI Part Number(s):                                                                                                                                     Issued by:

  Customer Name:                                               Customer Platform:                                 MEI Product:                            Status:

     Launch Activity         Date            Launch Activity         Date             Launch Activity        Date                       Action plan review                        Action plan review
                                                                                                                                 Date scheduled      Date actual           Date scheduled      Date actual




                                                                                                                                       Dates
  Item                          Concern / Problem / Open Issue
           Source of Issue                                                            Action                                                                        Status          Responsibility
 Number                                   Description                                                                Opened            Due           Closed




Distribution:
Supplier APQP: Progress Report - Status Overview

   Supplier Name:                                                 Supplier Location:                                                  Supplier Code:

   Part Number:                                                          Part Name:                                                   Revision Level:

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

PROGRAM MILESTONES
                                                       Date                                                                                   Date
          Event                                                                            Event
                                 Needed              Committed        Completed                                        Needed               Committed          Completed
Design Freeze
First Off-Tool
First Off-Process
ME PV Build
PPAP submission
Start of Production


PHASE/ELEMENT STATUS OVERVIEW

                                                                            Date                         Percent




                                                                                                                             Status
 APQP                                                                                                   Complete
                           Element                                                                                                        Issues / Recovery Plan / Actions
 Phase




                                                                                                                       100
                                                         Needed          Committed     Complete




                                                                                                   20
                                                                                                        40
                                                                                                             60
                                                                                                                  80
            1.1 Design FMEA
                  Preliminary Capacity Study
            1.2
                  reviewed
            1.3 Manufacturing Feasibility reviewed
    1
            1.4 Component Design Review
            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 Tooling
            2.3 Capital equipment
            2.4 Initiate PCM (Safe Launch Plan)
            2.5 Sub-Supplier PPAPs
            2.6 Process Flow Diagram
    2       2.7 PFMEA
            2.8 Control Plan
            2.9 Training
            2.1 Process instructions
            2.11 Packaging
            2.12 Launch Readiness Audit
            2.13 Key Supplier Metrics reviewed
            3.1 ELV/IMDS
            3.2 Safe Launch Plan finalized
            3.3 Supplier Ramp Plan
            3.4 Plant Readiness Review
    3
            3.5 Launch Readiness Audit
                  Appearance Approval Process
            3.6
                  (when applicable)
            3.7 Key Supplier Metrics reviewed
            4.1 PPAP
            4.2 Launch Readiness Audit
    4       4.3 Run at Rate
            4.4 Key Supplier Metrics reviewed
            4.5 OK to Launch Sign-Off
PPAP Submission Checklist
      Magna Part Number:                                       Description:                                             Revision Level:
      Customer:                                 Program:                                                Product Line:

                                 SUPPLIER INFORMATION                                                     MAGNA ELECTRONICS INFORMATION
      Company Name:                                                                                 Product Line:
      Company Location:                                                                             Using Location:
      Supplier Code:                                                                                Reviewer:
      Contact Name:                                     Phone:                                      Review Date:
      Contact email:                                                                                Disposition:

                                                                     PPAP Level 3 Unless MEI SDE directs "other"                                  Assessment
                                                                                                                            PPAP




                                                                                                                                                      Submitted
                                                                                                                          Submission




                                                                                                                                                                  Complete
                                                                                                                                           Required




                                                                                                                                                                                  Not OK
                                                                                                                            Level




                                                                                                                                                                             OK
No.                                                      Document                                                       1 2 3 4 5
1     Part Submission Warrant                                                                                           S S S S R
      A.   PART NUMBER INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
      B.   WEIGHT INCLUDED
      C.   SUPPLIER MANUFACTURING INFORMATION COMPLETE, INCLUDING SUPPLIER CODE
      D.   SUBMISSION INFORMATION COMPLETE.
            1. ALL APPROPRIATE BOXES CHECKED
            2. BUYER NAME INCLUDED
            3. APPLICATION INFORMATION INCLUDES MAGNA CUSTOMER AND PROGRAM
      E.   ELV/IMDS INFORMATION INCLUDED: The Magna Holly IMDS # is 9822
      F.   CORRECT REASON FOR SUBMISSION BOX CHECKED
            1. IF OTHER IS CHECKED, THAT THE CORRECT REASON FOR SUBMISSION IS NOTED
      G.   CORRECT SUBMISSION LEVEL BOX IS CHECKED
      H.   THE SUBMISSION RESULTS AREA IS PROPERLY FILLED OUT AND THE PACKAGE REFLECTS THIS
            1. PACKAGE CONTENTS MUST REFLECT SUPPLIER'S STATEMENT OF COMPLIANCE
            2. FOR MULTIPLE TOOLS/CAVITIES/PROCESSES THAT THE INFORMATION IS NOTED IF APPLICABLE
      I.   THE DECLARATION AREA CONTAINS THE RUN AT RATE INFORMATION
      J.   SIGNATURE AREA IS COMPLETED AND CONTAINS ALL INFORMATION

2     Design Records (Drawings, Specifications)                                                                         R S S     *    R
      A. A MARKED OR BALLOONED DRAWING IS ATTACHED. Note: All non reference print items and specs must be addressed.
      B. COPIES OF ALL REFERENCED SPECIFICATIONS ARE INCLUDED IN THE SUBMISSION (LEVEL 3 ONLY)
3     Change Documents                                                                                                  R S S     *    R
      A.   PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
      B.   PART APPLICATION / PROGRAM / PLANTS IDENTIFIED
      C.   SPECIFIES TIME SPAN OR VOLUME AFFECTED
      D.   ACTION PLAN INCLUDED IF REQUEST IS FOR DEVIATION/CONCESSION
      E.   SIGNED AND DATED BY MAGNA ENGINEERING

4     Customer Engineering Approval Documents                                                                           R R S     *    R
      A. IF PROCESS INCORPORATES UNRELEASED CHANGE, COPY OF ENGINEERING DOCUMENT INCLUDED

5     Design FMEA                                                                                                       R R S     *    R
      A.   PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
      B.   DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART?
      C.   DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT?
      D.   AREAS OF CONCERN IDENTIFIED IN THE DFMEA ARE CARRIED OVER INTO THE PFMEA.

6     Process Flow Diagram                                                                                              R R S     *    R
      A. PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
      B. MUST START WITH RECEIVING AND FINISH WITH SHIPMENT OF MATERIAL
      C. PROCESS FLOW DIAGRAM IS ACCURATE
7     Process FMEA                                                                                                      R R S     *    R
      A.   PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
      B.   DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART?
      C.   WHERE APPROPRIATE, DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT?
      D.   ARE CONCERNS INCLUDED THAT WERE DISCOVERED IN EARLY STAGES?
      E.   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.

8     Dimensional Results                                                                                               R S S     *    R
      A. ALL DIMENSIONS AND NOTES ON THE DRAWING ARE INCLUDED IN THE INSPECTION REPORT
           THERE IS A SEPARATE REPORT FOR EACH CAVITY, DIE, TOOL, LINE, ETC. EXCEPTIONS CAN ONLY BE
      B.
           GRANTED BY MAGNA SDE.

      C. WHEN SAMPLES ARE SUBMITTED, THE SAMPLE NUMBER CORRESPONDS WITH (SERIALIZED TO) THE DATA

           IF NON-CONFORMANCES ARE DOCUMENTED, THE WARRANT LETTER DOES NOT STATE COMPLIANCE. IT IS
      D.
           THE EXPECTATION OF MAGNA THAT NON-CONFORMANCES ARE RECONCILED PRIOR TO PPAP SUBMISSION.

      E. DIMENSIONS ARE REPORTED IN THE SAME UNITS AS ON THE MAGNA OR CUSTOMER DRAWING
      F. LAYOUTS OF SUBCOMPONENTS AND/OR ASSEMBLIES ARE DOCUMENTED AND AVAILABLE

9     Material & Performance Test Results                                                                               R S S     *    R
      A. ALL SPECIFICATIONS ON DRAWING ARE INCLUDED. COPIES OF ACTUAL SPECs ARE INCLUDED IN THE PACKAGE
      B. ACTUAL TEST LABORATORY DATA IS INCLUDED IN THE PACKAGE
      C. CERTIFIED LABORATORY USE (INCLUDED ARE COPIES OF CERTIFICATION AND SCOPE OF ACCREDITATION)
      D. DATA SHOWS TEST REQUIREMENTS AND RESULTS FOR EACH TEST, DETAILED IN EACH SPECIFICATION
           REFERENCED ON THE DRAWING
      E. MAGNA PART NUMBER AND REVISION LEVEL ARE INCLUDED ON EACH PAGE FOR ALL DATA

10 Initial Process Study                                                                                                R R S     *    R
    A. CAPABILITY STUDY RESULTS ARE SUBMITTED ON THE PRODUCT CHARACTERISTICS MATRIX
       (per MAGNA XXX)
    B. STUDIES ARE CONDUCTED FOR ALL CRITICAL AND SIGNIFICANT CHARACTERISTICS (EXCEPT DIMENSIONS
       WITH BONUS TOLERANCES). EACH STUDY MUST INCLUDE THE STUDY DATE.
    C. TEN (10) MEASUREMENTS FOR BONUS TOLERANCE DIMENSIONS ARE INCLUDED or PER MAGNA SDE DIRECTION
    D. PPK's FOR ALL CHARACTERISTICS ARE GREATER THAN, OR EQUAL TO, 1.67.
    E. IF NO, A WRITTEN CORRECTIVE ACTION STATEMENT, FOR EACH, IS INCLUDED AND CONTAINMENT, WHEN
         FEASIBLE, IS 100% INSPECTION.
    F. RAW DATA IS INCLUDED FOR EACH STUDY
    G. PROCESS AVERAGES MATCH FOR MULTIPLE CAVITIES, DIES AND TOOL PROCESSES.

11 Measurement Systems Analysis (Gage R&R)                                                                  R R S       *   R
    A.   STUDIES ARE INCLUDED (AND DATED) FOR GAGES USED TO MEASURE SIGNIFICANT AND CRITICAL DIMENSIONS.
    B.   GAGE R& R FORM IS USED FROM MEASUREMENT ANALYSIS HANDBOOK.
    C.   WRITTEN CORRECTIVE ACTIONS ARE INCLUDED FOR GAGE R&R'S GREATER THAN 30%.
    D.   THREE (3) OPERATORS, THREE (3) TRIALS ARE UTILIZED.
    E.   FORMS ARE COMPLETELY FILLED OUT.
    F.   WAS THE PROCESS CAPABILITY CALCULATED MADE OFF PARTS MADE FOR PPAP SUBMISSION?

12 Qualified Laboratory Documentation                                                                       R S S       *   R
    A. CERTIFICATE OF ACCREDITATION IS FROM A NATIONALLY RECOGNIZED ORGANIZATION.
    B. SCOPE OF ACCREDITATION IS INCLUDED.

13 Control Plan                                                                                             R R S       *   R
    A.   PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
    B.   DOES CONTROL PLAN REFLECTS LAUNCH PRACTICE ITEMS?
    C.   DOES IT SHOW SAME REVISION LEVEL AS PFMEA?
    D.   CONTROL PLAN ADDRESSES ALL SIGNIFICANT AND CRITICAL DIMENSIONS.
    E.   CONTROL PLAN ADDRESSES THE ENTIRE PROCESS FROM RECEIPT OF MATERIAL TO SHIPPING PRODUCT.
    F.   CONTROL PLAN INCLUDES ANNUAL REVALIDATION REQUIREMENTS.
    G.   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.

14 Appearance Approval Report (As Appropriate)                                                              S S S       *   R
15 Bulk Materials Requirement Checklist (As Appropriate)                                                    R R R       *   R
16 Sample Product                                                                                           R S S       *   R
17 Master Sample                                                                                            R R R       *   R
18 Checking Aids                                                                                            R R S       *   R
19 Compliance with Customer Specific Requirements                                                           R R S       *   R
    A. DOCUMENT(S) DEMONSTRATING COMPLIANCE WITH ANY OEM SPECIFIC COMMUNICATED REQUIREMENTS.

                                               Additional MAGNA SPECIFIC PPAP Requirements
20 Product Characteristic Matrix (per MAGNA XXX)                                                            *   *   S   *   *
    A. ALL SUB-TIER SUPPLIERS HAVE BEEN INCLUDED BASED ON SUPPLY CHAIN MAP.
    B. ALL SIGNIFICANT AND CRITICAL DIMENSIONS ARE INCLUDED, AND FOLLOW BACK TO THE MANUFACTURING
       PROCESS THAT PRODUCES THEM.
    C. PFMEA RPN'S ARE INCLUDED FOR ALL INCLUDED DIMENSIONS.
    D. CUSTOMER TOUCH POINTS AND CRITICAL PROCESS CONTROLLED DIMENSIONS ARE INCLUDED.
    E. SAFE LAUNCH PLAN DOCUMENTS CONTROLS THROUGHOUT THE SUPPLY CHAIN UP TO MAGNA.
21 Evidence of ELV / IMDS Approval                                                                          *   *   S   *   *
22 Packaging Plan and Sample Label (per MAGNA XXX)                                                          R R S       *   R

23 RUN-AT-RATE or Capacity Verification per MAGNA SDE DIRECTION (per MAGNA XXX)                             *   *   S   *   *
    A. DOES THE SUPPLIER NEED TO INCREASE THEIR CAPACITY?
    B. ARE BOTTLENECKS IDENTIFIED AND RESOLVED? ARE THERE ANY TOOLING CONSTRAINTS?
24 Sub - contractor PPAP status                                                                             S S S S R
    A. IS THERE A PSW FOR EACH COMPONENT AND MATERIAL IDENTIFIED IN THE BOM AND OR PCM?
    B. ARE THE PSW'S FULLY APPROVED? IF NOT, IS THERE A MAGNA DEVIATION/CONCESSION FOR EACH PSW NOT
       FULLY APPROVED?

25 Critical process approval (Heat treat, plating)                                                          S S S S R
    A. ARE THERE ANY CRITICAL SECONDARY PROCESSED THAT REQUIRES USE OF A RECOMMENDED SUPPLIER OR A
       MAGNA AUDIT BEFORE THEY ARE USED?

26 Certification of Review** (per MAGNA XXX)                                                                *   *   S S R
       APPLIES ONLY TO SUPPLIERS TO FOR WHICH THE COMMERCIAL SITUATION DOES NOT ALLOW
    A.
       FOR FULL DISCLOSURE.
                                             PPAP Submission Folder
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.
                                                                                                                    Part Number

                                                                                                                    Report Date / Revision
MEI APQP: Contacts- APQP TEAM
                                                                        Contact Information                                                  Contact Information

Function                                                                                      Function                                               Supplier
                       Name                                                                              Name
                       Dept.                                                                             Dept.
                       Tel.                                                                              Tel.
  MEI Purchasing
 Commodity Buyer
                       Fax.                                                                              Fax.
                       E-mail                                                                            E-mail
                       Address/                                                                          Address/
                       Location                                                                          Location
                       Name                                                                              Name
                       Dept.                                                                             Dept.
                       Tel.                                                                              Tel.
  MEI Purchasing
  Program Buyer
                       Fax.                                                                              Fax.
                       E-mail                                                                            E-mail
                       Address/                                                                          Address/
                       Location                                                                          Location
                       Name       Chris Hempsall                                                         Name
                       Dept.      Purchasing                                                             Dept.
   MEI Supplier        Tel.       810-603-4137                                                           Tel.
   Development         Fax.                                                                              Fax.
   Engineering         E-mail     chris.hempsall@magnaelectronics.com                                    E-mail
                       Address/                                                                          Address/
                       Location                                                                          Location
                       Name                                                                              Name
                       Dept.                                                                             Dept.
                       Tel.                                                                              Tel.
  MEI Engineering      Fax.                                                                              Fax.
                       E-mail                                                                            E-mail
                       Address/                                                                          Address/
                       Location                                                                          Location
                       Name                                                                              Name
                       Dept.                                                                             Dept.
                       Tel.                                                                              Tel.
 MEI Receiving Plant
Logistic & Packaging
                       Fax.                                                                              Fax.
                       E-mail                                                                            E-mail
                       Address/                                                                          Address/
                       Location                                                                          Location
                       Name                                                                              Name
                       Dept.                                                                             Dept.
                       Tel.                                                                              Tel.
MEI Receiving Plant
      Quality
                       Fax.                                                                              Fax.
                       E-mail                                                                            E-mail
                       Address/                                                                          Address/
                       Location                                                                          Location
                       Name                                                                              Name
                       Dept.                                                                             Dept.
                       Tel.                                                                              Tel.
Project Management     Fax.                                                                              Fax.
                       E-mail                                                                            E-mail
                       Address/                                                                          Address/
                       Location                                                                          Location

								
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