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					Supplier APQP Workbook



        Supplier Name:                          Supplier Location:      Supplier Code:

        Part Number:                            Part Name:              Revision Level:

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




Date: 16 Jan 2008                                                                               Process Owner / Department:
Revision: D                                                     Cover                     R. Spariosu / Supplier Development
Doc No: D_020_4_03                                                                                               Approved by:
Page 1 of 26                                                                              R. Blanchette / Global Director, SDE
    Supplier APQP: Five Phases
                                                                               GSQM
                                                                             MANAGEMENT MESSAGE



                                    SUPPLIER
                                                                                                                                            OTHER SUPPLIER
                                 REQUIREMENTS &                                   APQP                                                      REQUIREMENTS
                                   SELECTION


         PHASE 1                                PHASE 2                            PHASE 3                                                                 PHASE 5
                                                                                                                      PHASE 4
      Supplier Kick-                        Equipment & Tool                    Product/Process                                                       Product/Process
                                                                                                                      Pre-PPAP
      off & Planning                             Design                           Realization                                                        Validation & Launch



          Identify TRW & Supplier team          Preliminary Process Flow,               Supplier Packaging                                                   Finalize complete PPAP
                                                                                                                        Pre-Production Run
          contacts/roles/responsibilities      PFMEA & Control Plan review                Requirements                                                         submission package

           Communicate & initiate Key            Review Supplier DFMEA              Analysis of process failures                                         Cross-functional Key Metrics
                                                                                                                     Process Capability Study
               Supplier Metrics                     (when applicable)                       and effects                                                  review; OK to launch sign-off

           Initial supplier program plan        Create PCM; Identify sub-                                            Finalize PCM; Prepare for
                                                                                        Process Flow Chart                                                 Launch Readiness Audit
                     and timing                   supplier value chain                                                      Safe Launch

            Conduct cross-functional             Supplier master schedule            Use PCM for Pre-Launch         Finalize PFMEA and Control            Confirmation of full volume
            component design review                       review                          Control Plan                         Plan                              Run at Rate

                                                                                                                     Launch Readiness Audit;
               APQP requirements               Review Key Supplier Metrics              Process Instructions                                             Initiate Safe Launch Practice
                                                                                                                     document in Key Metrics

           Equipment, tooling & gage           Update previous phase open            Finalize process capability                                         Final component packaging
                                                                                                                        Supplier Ramp Plan
                design review                    issues/key documents                        study plan                                                            review

             Create APQP Progress                                                   Validation review of off-tool     Re-qualify equipment /
                                                                                                                                                         Review Key Supplier Metrics
                     Report                                                                  condition              tooling/ gauging at supplier

               Initiate Open Issues                                                                                    Appearance Approval                Close out previous phase
                                                                                         Floor plan layout
                     document                                                                                           (when applicable)                open issues/key documents

          Review Preliminary Capacity                                                 Pre-qualify equipment /       Supplier participates in Plant
                    Study                                                           tooling / gauging at supplier       Readiness Review

                                                                                       Review Key Supplier
             Review Manufacturing                                                                                   Review Key Supplier Metrics
                                                                                             Metrics
                  Feasibility
                                                                                      Update previous phase         Update previous phase open
                                                                                    open issues/key documents         issues/key documents




Date: 16 Jan 2008                                                                         5 Phases                                                           Process Owner/Department:
Revision: D                                                                                                                                          R. Spariosu / Supplier Development
Doc No.: D_020_4_03                                     SUPPLIER SENIOR MANAGEMENT SUPPORT                                                                                  Approved by:
Page 2 of 26                                                                                                                                         R. Blanchette / Global Director, SDE
Supplier APQP: Table of Contents
 Cover                      Shows the 5 APQP Phases and the activities that occur within them.

 Table of Contents          Lists all of the forms and examples included in this workbook.

 Introduction               Displays a pictorial representation of APQP elements tracked in the Progress Report in relationship to
                            TRW's launch profile.

 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 Report         Key Metrics contain those elements that contribute to a successful launch. This form allows for five
                            reviews. The minimum requirement is to use it at APQP-5. The APQP-5 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.




 Key Metrics Graph          Visually displays and compares the results of the Key Metrics reports generated during APQP-4 and/or
                            APQP-5.

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



 Progress Report            Reporting form for suppliers to track progress on all APQP deliverables.

 Other APQP Tools           Embedded copies of the Component Design Review, Product Characterisitics Matrix, and Launch
                            Readiness Audit.

 Supply Chain Map           Form for showing multi-tier suppy chain relationships involved in providing the component/assembly to
                            TRW. The information documented here will also be used in the creation of the Product Characteristics
                            Matrix.

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

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


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



 In Cell Check (Blank)      This form is used document inspection results for those characteristics and features identified on the
                            Product Characteristics Matrix during the Safe Launch Plan implementation period.




 Date: 16 Jan 2008                                       Table of Contents                                  Process Owner/Department:
 Revision: D                                                                                         R. Sparisou / Supplier Development
 Doc No.: D_020_4_03                                                                                                        Approved by:
 Page 3 of 26                                                                                         R. Spariosu / Global Director, SDE
Supplier APQP: Table of Contents
 In Cell Check         An example of the In Cell Check.
 (Example)

 SLP - Weekly QOS      Format to be used for a weekly summary of the inspection results from the Safe Launch Plan.
 Report

 Open Issues           The action plan format used to document open issues, their actions and resolution throughout the
                       APQP process. This combines several different action plans generated by different, individual tools into
                       a single document.

 Contacts              Lists the individuals involved in the component(s) launch, for both TRW and the supplier, and their
                       respective contact information. This tab is optional and may be used as needed.




 Date: 16 Jan 2008                                Table of Contents                                Process Owner/Department:
 Revision: D                                                                                R. Sparisou / Supplier Development
 Doc No.: D_020_4_03                                                                                               Approved by:
 Page 4 of 26                                                                                R. Spariosu / Global Director, SDE
Supplier APQP: Five Phase Time Line
The TRW Automotive Supplier Advanced Product Quality Planning (APQP) process consists of 5 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 5 Phases, their deliverables and the Global Development & Product Introduction Management process.

This workbook consists of 10 forms in support of this process. Suppliers are expected to use this process regardless of the priority ranking assigned components/materials requiring submission of a PPAP package.
                                                                                                                                                                      New Product Launch Profile (GDPIM Phases)
                      APQP PHASE




                                                                                                                                                                                                                                                     7: TRW Customer
                                                                                                                                                                                                                                  6: Supplier PPAP
                                                                                                                         5: Supplier Kick-




                                                                                                                                                  5: Supplier Tool,
                                                                                         Requests, Early




                                                                                                                                                   Gauge Design
                                                                                                                                                     Equipment,




                                                                                                                                                                                                   Realization




                                                                                                                                                                                                                                                                       Production
                                                                                                                                                                                                   6: Supplier
                                                                                                           4: Finalize




                                                                                                                                                                                                                                                                       8: Start of
                                                                                           Sourcing




                                                                                                           Sourcing
                                                                                            2: Quote




                                                                                                                                                                                                    Process




                                                                                                                                                                                                                                                          PPAP
                                                                                                                               Off
                                                         OUTPUT



                                   1.1   Design FMEA
    Supplier Kick-Off




                                   1.2   Preliminary Capacity Study 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   Sub contractor PPAP approval
 Equipment & Tool




                                   2.2   Product Characteristic Matrix initiated
      Design




                                   2.3   Process flow chart
        2.




                                   2.4   PFMEA
                                   2.5   Control Plan
                                   2.6   Appearance Approval Process (when applicable)
                                   2.7   Key Supplier Metrics reviewed
                                   3.1   Measurement/ Testing equipment
 Product/Production




                                   3.2   Tooling
                                   3.3   Capital equipment
     Realization




                                   3.4   Training
         3.




                                   3.5   Process instructions
                                   3.6   Quality System and Plan review
                                   3.7   Packaging
                                   3.8   Launch Readiness Audit
                                   3.9   Key Supplier Metrics reviewed
                                   4.1   ELV/IMDS
                                   4.2   Safe Launch Plan finalized
    Pre-PPAP




                                   4.3   Supplier Ramp Plan
        4.




                                   4.4   Plant Readiness Review
                                   4.5   Launch Readiness Audit
                                   4.6   Key Supplier Metrics reviewed
Product/Proc




                                   5.1   PPAP
Validation &




                                   5.2   Launch Readiness Audit
    ess
     5.




                                   5.3   Run at Rate
                                   5.4   Key Supplier Metrics reviewed
                                   5.5   OK to Launch Sign-Off




                 Date: 16 Jan 2005                                                                                                           Introduction                                                                Process Owner/Department:
                 Revision: D                                                                                                                                                                                      R. Spariosu / Supplier Development
                 Doc No.: D_020_4_03                                                                                                                                                                                                     Approved by:
                 Page 5 of 26                                                                                                                                                                                     R. Blanchette / Global Director, SDE
Supplier APQP: Blank Time Line
                                                                                                                                          Year 1                                                                                                                             Year 2
    PHASE
    APQP




                                              OUTPUT




                                                                              02
                                                                                   04
                                                                                        06
                                                                                             08
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                                                                                                                                                                                                                 02
                                                                                                                                                                                                                      04
                                                                                                                                                                                                                           06
                                                                                                                                                                                                                                08
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                                                                                                                                                                                                                                          12
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                                                                                                                                                                                                                                                                        24
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                                                                                                                                                                                                                                                                                                                                     48
                                                                                                                                                                                                                                                                                                                                          50
                                                                                                                                                                                                                                                                                                                                               52
                        1.1   Design FMEA
    Supplier Kick-Off




                        1.2   Preliminary Capacity Study 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   Sub contractor PPAP approval
 Equipment &
 Tool Design




                        2.2   Product Characteristic Matrix initiated
                        2.3   Process flow chart
      2.




                        2.4   PFMEA
                        2.5   Control Plan
                        2.6   Key Supplier Metrics reviewed
                        3.1   Measurement/ Testing equipment
 Product/Productio
   n Realization




                        3.2   Tooling
                        3.3   Capital equipment
         3.




                        3.4   Training
                        3.5   Process instructions
                        3.6   Packaging
                        3.7   Key Supplier Metrics reviewed
                        4.1   ELV/IMDS
                        4.2   Safe Launch Plan finalized
    Pre-PPAP




                        4.3   Supplier Ramp Plan
        4.




                        4.4   Plant Readiness Review
                        4.5   Launch Readiness Audit
                        4.6   Appearance Approval Process (when applicable)
                        4.7   Key Supplier Metrics reviewed
Validation &




                        5.1   PPAP
 Product/
 Process




                        5.2   Launch Readiness Audit
     5.




                        5.3   Run at Rate
                        5.4   Key Supplier Metrics reviewed
                        5.5   OK to Launch Sign-Off
                        6.1
 Requirements




                        6.2
                        6.3
    Other
      6.




                        6.4
                        6.5
                        6.6
                        6.7


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




            Date: 16 Jan 2008                                                                                                                  Blank Time Line                                                                                                                           Process Owner/Department:
            Revision: D                                                                                                                                                                                                                                                           R. Spariosu / Supplier Development
            Doc No.: D_020_4_03                                                                                                                                                                                                                                                                          Approved by:
            Page 6 of 26                                                                                                                                                                                                                                                          R. Blanchette / Global Director, SDE
Supplier APQP: Key Metrics Elements Graph

     Supplier Name:       0                                            Supplier Location:   0                                                                                            Supplier Code:                                  0


     Part Number:         0                                            Part Name:     0                                                                                                  Revision Level:                                 0


     Component Priority Level:        0                    Lead Customer/Program:     0                                                                                                  Report Date:                                    0-Jan-1900


CLICK ON THE BUTTON TO UPDATE THE "KEY METRICS STATUS" GRAPH:


                                      Key Metrics Status                                                                                                                                       Primary Indicators
    100%                                                                                        100%




     80%                                                                                        80%




                                                                                                60%
     60%


                    12           12               12          12             12
                                                                                                40%
     40%




                                                                                                           APQP Readiness




                                                                                                                                                           APQP Readiness




                                                                                                                                                                                                          APQP Readiness




                                                                                                                                                                                                                                                           APQP Readiness




                                                                                                                                                                                                                                                                                                          APQP Readiness
                                                                                                20%




                                                                                                                                               GSQM 220




                                                                                                                                                                                               GSQM 220




                                                                                                                                                                                                                                                                                               GSQM 220




                                                                                                                                                                                                                                                                                                                                              GSQM 220
                                                                                                                                                                                                                                               GSQM 220
                                                                                                                            Capability




                                                                                                                                                                            Capability




                                                                                                                                                                                                                            Capability




                                                                                                                                                                                                                                                                            Capability




                                                                                                                                                                                                                                                                                                                           Capability
     20%




                                                                                                                                                                                         LRA




                                                                                                                                                                                                                                         LRA




                                                                                                                                                                                                                                                                                                                                        LRA
                                                                                                                                         LRA




                                                                                                                                                                                                                                                                                         LRA
                                                                                                 0%




                                                                                                                               0-Jan-




                                                                                                                                                                               0-Jan-




                                                                                                                                                                                                                               0-Jan-




                                                                                                                                                                                                                                                                               0-Jan-




                                                                                                                                                                                                                                                                                                                              0-Jan-
                                                                                                                                                                                 00




                                                                                                                                                                                                                                 00




                                                                                                                                                                                                                                                                                 00




                                                                                                                                                                                                                                                                                                                                00
                                                                                                                                 00
      0%            0            0                 0           0              0




                                                                           Key Metric Values at Review


                                                                                  APQP Readiness
                                                                             100.0%
                                                       GSQM 220                                                                                           Instructions
                                                                                  80.0%

                                                                                  60.0%
                                 Ramp Plan                                                                                                                                                                FTC
                                                                                  40.0%

                                                                                  20.0%

               PPAP Completion                                                      0.0%                                                                                                                                                 Process Efficiency




                           Sub-Tier PPAP                                                                                                                                                                  Capability



                                                              LRA                                                                                         Testing

                                                                              % Process Complete

                                             0-Jan-00              0-Jan-00                 0-Jan-00                                                 0-Jan-00                                                              0-Jan-00




  Date: 16 Jan 2008                                                                  APQP Element Graphs                                                                                                                                                          Process Owner/Department:
  Revision: D                                                                                                                                                                                                                                             R. Spariosu / Supplier Development
  Doc No.: D_020_4_03                                                                                                                                                                                                                                                            Approved by:
  Page 7 of 26                                                                                                                                                                                                                                            R. Blanchette / Global Director, SDE
Supplier APQP: Key Supplier Metrics Report

       Supplier Name:                          0                                                  Supplier Location:   0                                    Supplier Code:    0

       Part Number:                            0                                                  Part Name:      0                                         Revision Level:   0

       Component Priority Level:                           0                      Lead Customer/Program:          0                                         Report Date:      0-Jan-1900


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
         MANUFACTURABILITY




                                                               Total number of instructions needed.
                                                               Results from Run at Rate, line 25
                              3. First Time Capability
                                                               Ideal % of good parts
  K
                                                               Overall Utilization percentage.
  E                           4. Process Efficiency
  Y                                                            Maximum allowable utilization
                                                               Number of capable designated characteristics features
 M                            5. Process Capability
 E                                                             Total number of designated characteristics features
 A                                                             Number of tests passed
 S                            6. Test Achievement
                                                               % of total tests
 U
 R                            7. Process Implementation -      High volulme process or Interim Process with Concession
 E                            % Completed                      Production volumes provided off production intent process               5
 A                                                             Score achieved during event
 B                            8. Launch Readiness Audit
         PPAP




                                                               Goal is 100%.
 L
 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




                                                               Enter completed stage of PCM (see comments)
                              12. GSQM 220 Deployment
                                                               Complete Stage 5 by SOP                                                 5




SUPPLIER SIGN-OFF (MANAGER LEVEL)

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

                       Name (print)
                             Signature



TRW SIGN-0FF
                                                    SDE                            Name (print)                                      Signature
      TRW Internal Use only                         Commodity Mgr/Buyer            Name (print)                                      Signature
                                                    SQA                            Name (print)                                      Signature




      Date: 16 Jan 2008                                                                                   Key Metrics Report                                                  Process Owner/Department:
      Revision: D                                                                                                                                                     R. Spariosu / Supplier Development
      Doc No.: D_020_4_03                                                                                                                                                                    Approved by:
      Page 8 of 26                                                                                                                                                    R. Blanchette / Global Director, SDE
APQP: Key Supplier Metrics Operational Definitions
This section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five
phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP appro



          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 33 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
                           Form No.: D_020_4_12
                                                                        production of 100% good, or usable, parts.

Process Efficiency         This is the percentage that the process is                                                The Overall Utilization % from the Run at
                           utilized.                                                                                 Rate form.

                                                                        Maximum allowable utilized capacity is
                                                                        100% when the standard shift pattern and
                                                                        CPV are used.
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.




Date: 16 Jan 2008                                                  Key Metrics Definitions                                            Process Owner/Department:
Revision: D                                                                                                                    R. Sparisou / Supplier Development
Doc No.: D_020_4_03                                                                                                                                   Approved by:
Page 9 of 26                                                                                                                   R. Blanchette / Global Director, SDE
APQP: Key Supplier Metrics Operational Definitions
This section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five
phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP appro



          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. Intermim 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 TRW.                                                            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 comprehesive audit tool's score, which                                                 The score achieved on the Launch
                           assesses a process's state of preparation                                                Readiness Audit. Enter data as a
                           to meet serial production requirements.                                                  decimal number.
                                                                       The minimum goal for full release for
                           Form No.: D_020_4_09
                                                                       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
                           TRW.                                      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.




Date: 16 Jan 2008                                                  Key Metrics Definitions                                          Process Owner/Department:
Revision: D                                                                                                                  R. Sparisou / Supplier Development
Doc No.: D_020_4_03                                                                                                                                 Approved by:
Page 10 of 26                                                                                                                R. Blanchette / Global Director, SDE
APQP: Key Supplier Metrics Operational Definitions
This section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five
phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP appro



          Metric                           Definition                                         Goal                                     Results

APQP Readiness
Supplier Ramp Plan         Data element evaluates a supplier's ability
                           This is derived from the 'APQP Progress                                                    Enter the number corresponding to the
                           Report'. ramp-up timing andthe
                           to meet This metric tracks volumes.                                                        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.
GSQM 220 Deployment        This element provides status of the                                                        Enter number of completed stage at time
                           completion of the safe launch plan, on                                                     of review.
                           the PCM (D_020_4_20).                         Enter the number '5' representing the
                                                                         completion of the PCM, less the exit from
                                                                         the Safe Launch Plan. This applies to
                                                                         situations where the PPAP will be
                                                                         submitted in a span of time from before
                                                                         SOP to 30 days after SOP.

                                                                         Enter the number '6' for situations where
                                                                         the SLP exit is required for closing APQP.




Date: 16 Jan 2008                                                   Key Metrics Definitions                                           Process Owner/Department:
Revision: D                                                                                                                    R. Sparisou / Supplier Development
Doc No.: D_020_4_03                                                                                                                                   Approved by:
Page 11 of 26                                                                                                                  R. Blanchette / Global Director, SDE
Supplier APQP: Progress Report - Status Overview


   Supplier Name:        0                                           Supplier Location:           0                                   Supplier Code:     0

   Part Number:          0                                                  Part Name:    0                                           Revision Level:    0

   Component Priority Level:             0                    Lead Customer/Program:      0                                           Report Date:       0-Jan-1900


PROGRAM MILESTONES

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



PHASE/ELEMENT STATUS OVERVIEW




                                                                                                                             Status
 APQP                                                                          Date                            Percent
                             Element                                                                                                     Issues / Recovery Plan / Actions




                                                                                                                   100
 Phase                                                      Needed          Committed         Complete        20
                                                                                                              40
                                                                                                                   60
                                                                                                                   80
             1.1   Design FMEA
             1.2   Preliminary Capacity Study
             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   Subcontractor PPAP approval
             2.2   Product Characteristic Matrix
             2.3   Process flow chart
    2
             2.4   PFMEA
             2.5   Control Plan
             2.6   Key Supplier Metrics reviewed
             3.1   Measurement/ Testing equipment
             3.2   Tooling
             3.3   Capital equipment
             3.4   Training
    3
             3.5   Process instructions
             3.6   Packaging
             3.7   Launch Readiness Audit
             3.8   Key Supplier Metrics reviewed
             4.1   ELV/IMDS
             4.2   Safe Launch Plan finalized
             4.3   Supplier Ramp Plan
    4        4.4   Plant Readiness Review
             4.5   Launch Readiness Audit
             4.6   Appearance Approval Process
             4.7   Key Supplier Metrics reviewed
             5.1   PPAP
             5.2   Launch Readiness Audit
    5        5.3   Run at Rate
             5.4   Key Supplier Metrics reviewed
             5.5   OK to Launch Sign-Off




        Date: 16 Jan 2008                                                       Progress Report                                              Process Owner/Department:
        Revision: D                                                                                                                   R. Spariosu / Supplier Development
        Doc No.: D_020_4_05                                                                                                                                  Approved by:
        Page 12 of 26                                                                                                                 R. Blanchette / Global Director, SDE
Supplier APQP: Other Tools


 COMPONENT DESIGN REVIEW

                                                               CLICK HERE




 PRODUCT CHARACTERISTICS
 MATRIX

                                                               CLICK HERE




 LAUNCH READINESS AUDIT

                                                               CLICK HERE




 PPAP CHECKLIST

                                                               CLICK HERE




 Date: 16 Jan 2008     Other APQP Tools           Process Owner/Department:
 Revision: D                              R. Sparisou / Supplier Development
 Doc No.: D_020_4_03                                             Approved by:
 Page 13 of 26                            R. Blanchette / Global Director, SDE
Supplier APQP: Supply Chain Map
  Supplier:         0                Part Number:   0                                Date:                             Revision:

                                                                                  TRW receiving     OEM
     Tier V                Tier IV    Tier III                 Tier II              Operation
                                                                                                                                         Tier
                                                                                                  Customer




     Date: 16 Jan 2008                                  Supply Chain Map - Form                                     Process Owner/Department:
     Revision: D                                                                                             R. Spariosu / Supplier Development
     Doc No.: D_020_4_03                                                                                                            Approved by:
     Page 14 of 26                                                                                           R. Blanchette / Global Director, SDE
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                                                    TRW Mesa
                                                                                                                       Saf-Store                               Mesa, AZ
                                                                                                                       Mesa, AZ                               OEM Z910
                            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
                                                                                                                                                              TRW Alfdorf
      C1024 Rod               C1024 Rod
                                                                                                                                                            Alfdorf, Germany
       Steel Mill          Wire Draw, Anneal
                                                                                                                                                               OEM Z910




                           Dynamic Chemical
                               Supplies           Zephyr Coatings
                               Tulsa, OK             Austin, TX
                            Coating materials,        E-Coat
                                solvents




     Date: 16 Jan 2008                                                  Supplier Chain Map - Example                                                        Process Owner:
     Revision: D                                                                                                                        R. Spariosu / Supplier Development
     Doc No.: D_020_4_03                                                                                                                                       Approved by:
     Page 15 of 26                                                                                                                      R. Blanchette / Global Director, SDE
Supplier APQP: Product Characteristic Matrix
                   Part Name:                                                                           Supplier Name:                                                         PCM Revision Date:


       Part Number/ Revision:                                                                                 Location:


             Project/ Program:                                                                      TRW Using Plant(s):




             Product Design Inputs                                                      Supplier Process Control Information                                           Safe Launch Plan (SLP)
#
                                 Level/   DFMEA      PFMEA       PFMEA       PFMEA
    Product Characteristic                                                                 RPN      Control Method(s)     Gauge R&R   Sample Size / Frequency   Control Method               Sample Size / Frequency
                                 Class    Severity   Severity   Occurance   Detection




        Date: 29 April 2008                                                                        D_020_4_20-PCM                                                          Process Owner/Department:
        Revision: B                                                                                                                                                R. Blanchette / Supplier Development
        Doc No: D.020.4.20                                                                                                                                                                  Approved by:
        Page 16 of 26                                                                                                                                                                    / VP Purchasing
Supplier APQP: Product Characteristic Matrix
                        Part Name:                                                                             Supplier Name:                                                             PCM Revision Date:


            Part Number/ Revision:                                                                                   Location:


                  Project/ Program:                                                                        TRW Using Plant(s):




                  Product Design Inputs                                                        Supplier Process Control Information                                               Safe Launch Plan (SLP)
 #
                                      Level/   DFMEA        PFMEA       PFMEA       PFMEA
         Product Characteristic                                                                   RPN      Control Method(s)         Gauge R&R   Sample Size / Frequency   Control Method               Sample Size / Frequency
                                      Class    Severity     Severity   Occurance   Detection




Safe Launch Plan duration is for 90 days after start of production unless otherwise specified.                                                                 Other:
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
SLP data must be sent to TRW (check one):                                             Daily              Weekly                  Monthly         Each Shipment                Other
Safe Launch Plan must remain in effect until TRW approves SLP exit.
All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced
during PPAP.
                                                                                                        PCM APPROVALS
                                                          Name                       Position/ Title                              Signature                      Date                       Comments
TRWA SDE

TRWA Plant SQA

Supplier Representative




             Date: 29 April 2008                                                                          D_020_4_20-PCM                                                              Process Owner/Department:
             Revision: B                                                                                                                                                      R. Blanchette / Supplier Development
             Doc No: D.020.4.20                                                                                                                                                                        Approved by:
             Page 17 of 26                                                                                                                                                                          / VP Purchasing
Supplier APQP: Safe Launch Plan Data and Exit Approval
                   Part Name:                                                                                      Supplier Name:                                                PCM Revision Date:


       Part Number/ Revision:                                                                                            Location:


             Project/ Program:                                                                                 TRW Using Plant(s):




      Product Design Inputs                      Safe Launch Plan (SLP)                                Date:                                Date:                        Date:
                                                                                           Cpk from
#
                                 Level/                                                     PPAP       Quantity        Quantity             Quantity   Quantity          Quantity       Quantity
    Product Characteristic                Control Method         Sample Size / Frequency                                             Ppk                          Ppk                                        Ppk
                                 Class                                                                Inspected        Rejected            Inspected   Rejected         Inspected       Rejected




           Date: 25 Apr 2008                                                                                                                                                         Process Owner/Department:
           Revision: B                                                                                                                                                      R. Blanchette / Supplier Development
           Doc No: D.020.4.20                                                                                                                                                                        Approved by:
           Page 18 of 26                                                                                 D_020_4_20-SLP                                                                          / VP Purchasing
Safe Launch Plan duration is for 90 days after start of production unless otherwise specified.                Other:
Enter accumulated production data where specified in this form. Use of the SLP Weekly QOS Form will be directed by TRW as necessary.
Submit data to the TRW Plant per the agreed frequency on the Product Characteristic Matrix unless instructed otherwise by TRW.
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
To exit SLP: Sign and submit this form with all data. Acceptablilty of SLP exit request will be determined by TRW SQA.

                                                                         SAFE LAUNCH PLAN EXIT APPROVALS
                                           Name                            Position/ Title                     Signature         Date      Comments

Supplier Representative
TRWA Plant SQA




               Date: 25 Apr 2008                                                                                                                 Process Owner/Department:
               Revision: B                                                                                                              R. Blanchette / Supplier Development
               Doc No: D.020.4.20                                                                                                                                Approved by:
               Page 19 of 26                                                                 D_020_4_20-SLP                                                  / VP Purchasing
Safe Launch Plan: QOS Report

                                      Touch Point Incident & PPM Monitoring                                                                                                               Pareto Failures By Process

                   1                                                                                         1                              1

                                                                                                             1                             0.9
                   1
                                                                                                             1                             0.8

                                                                                                             1                             0.7
                   1
                                                                                                             1                             0.6
        Incident




                                                                                                                 PPM




                                                                                                                                Incident
                   1                                                                                         1
                                                                                                                                           0.5
                                                                                                             0
                                                                                                                                           0.4
                   0
                                                                                                             0
                                                                                                                                           0.3
                                                                                                             0
                   0                                                                                                                       0.2
                                                                                                             0
                                                                                                                                           0.1
                   0                                                                                         0
                                                                                                                                                   0   0      0    0        0      0       0     0    0      0     0       0       0     0         0    0        0      0      0      0      0
                                                                                                                                            0
                                                        Incidents   PPM




                                                                           Total     WEEK
                                                                            0       Incidents
                                                                            0         QTY
                                                                          #DIV/0!     PPM          #DIV/0!        #DIV/0!    #DIV/0!         #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.
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0
                                                 0




 Date: 01 Aug 2005                                                                              D_020_4_20-SLP - QOS                                                                                                                                                Process Owner/Department:
 Revision: C                                                                                                                                                                                                                                                     K. Gillis / Supplier Development
 Doc No: D_020_4_05                                                                                                                                                                                                                                                                   Approved by:
 Page 20 of 26                                                                                                                                                                                                                                                    E. Carpenter / VP Purchasing
Supplier APQP: Product Characteristic Matrix
                   Part Name:                                                                           Supplier Name:                                                           PCM Revision Date:


       Part Number/ Revision:                                                                                 Location:


             Project/ Program:                                                                      TRW Using Plant(s):




             Product Design Inputs                                                      Supplier Process Control Information                                             Safe Launch Plan (SLP)
#
                                 Level/   DFMEA      PFMEA       PFMEA       PFMEA
    Product Characteristic                                                                 RPN      Control Method(s)       Gauge R&R   Sample Size / Frequency   Control Method               Sample Size / Frequency
                                 Class    Severity   Severity   Occurance   Detection




        Date: 29 April 2008                                                                   D_020_4_20-PCM Sub-Supplier                                                    Process Owner/Department:
        Revision: B                                                                                                                                                  R. Blanchette / Supplier Development
        Doc No: D.020.4.20                                                                                                                                                                    Approved by:
        Page 21 of 26                                                                                                                                                                      / VP Purchasing
Supplier APQP: Product Characteristic Matrix
                        Part Name:                                                                               Supplier Name:                                                              PCM Revision Date:


            Part Number/ Revision:                                                                                     Location:


                  Project/ Program:                                                                          TRW Using Plant(s):




                  Product Design Inputs                                                        Supplier Process Control Information                                                  Safe Launch Plan (SLP)
 #
                                      Level/   DFMEA        PFMEA       PFMEA       PFMEA
         Product Characteristic                                                                   RPN        Control Method(s)          Gauge R&R   Sample Size / Frequency   Control Method               Sample Size / Frequency
                                      Class    Severity     Severity   Occurance   Detection




Safe Launch Plan duration is for 90 days after start of production unless otherwise specified.                                                                    Other:
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
SLP data must be sent to TRW (check one):                                             Daily                Weekly                  Monthly          Each Shipment                Other
Safe Launch Plan must remain in effect until TRW approves SLP exit.
All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced
during PPAP.
                                                                                                        PCM APPROVALS
                                                          Name                       Position/ Title                                 Signature                      Date                       Comments
TRWA SDE

TRWA Plant SQA

Supplier Representative




             Date: 29 April 2008                                                                       D_020_4_20-PCM Sub-Supplier                                                       Process Owner/Department:
             Revision: B                                                                                                                                                         R. Blanchette / Supplier Development
             Doc No: D.020.4.20                                                                                                                                                                           Approved by:
             Page 22 of 26                                                                                                                                                                             / VP Purchasing
                                100% IN CELL KEY FEATURES VERIFICATION
                                      AND CUSTOMER TOUCH POINTS
                                        FEATURES TO BE QUALIFIED
Part Description




                       Operator Name:___________ Work Cell:_________

                       Quantity Inspected:____________Date:______________




                                                                                                        Pass
                                                                                Verification




                                                                                                                            Fail
                                                                                Method
   1

   2

   3

   4

   5

   6

   7

   8

   9

10




                                                                                                         The Items Qualified Are To
                       COMMENTS :




                                                                                                              "YELLOW" Paint.
                                                                                                               Be Marked With
Part Number




                       Supervisor Signature :                     Date :




  Date: 16 Jan 2008                               In Cell Check                     Process Owner/Department:
  Revision: D                                                               R. Spariosu / Supplier Development
  Doc No: D_020_4_03                                                                               Approved by:
  Page 23 of 26                                                             R. Blanchette / Global Director, SDE
        Safe Launch Plan: In Cell Check Example
                              TRW
                           Automotive                                            Special Work Instruction
       Customer /Project:                                                                                  Part No.       issue   Station   Document No.         Rev    Issue date
                                                                 Part/ Process Description :
          ADVICS / IMV                                         Save lunch checking item Station15           145-44001                                               0   23 April'04
                                                                                                           /145-44002             15                                     Sheet 1/1

        OPERATION OP25 SAFE LAUNCH PRODUCTION




                                                                             1

                                    2

                                                           3                                                                                           6


                                                                                                                                            Example

                                                                                                                                            5
                                                    4




                                                                                            FEATURES TO BE QUALIFIED
        Part Description




                                                               Operator Name:___________ Work Cell:_________
                                           Brake Assy RH
                           Brake Assy LH




                                                                                                                                                                           Pass



                                                               Quantity Inspected:____________Date:______________                                 Verification
                                                                                                                                                                                  Fail


                                                                                                                                                  Method
              1              *               *                 Lining identification code                                                                  Visual
              2              *               *                 Mass weight and rivet presence                                                              Visual
              3              *               *                 Date code on shoe                                                                           Visual
              4              *               *                 PKB rivet crimped washer                                                                    Visual

              5              *               *                 Pkb lever hook                                                                        Gap Gauge
                                                                                                                                                     Air Torque
              6
                             * *                               Wheel cylinder screw torque                                                              /mark
                                                                                                                                                                         Qualified Are

                                                                                                                                                                         Marked With




                                                               COMMENTS :
                                                                                                                                                                          "YELLOW"
                                                                                                                                                                           The Items
         Part Number




                                                                                                                                                                             To Be
                           14544002
                                           14544001




                                                               Supervisor Signature :                                   Date :

Date: 16 Jan 2008                                                                                   In Cell (Example)                                              Process Owner/Department:
Revision: D                                                                                                                                                R. Spariosu / Supplier Development
Doc No: D_020_4_03                                                                                                                                                                Approved by:
Page 24 of 26                                                                                                                                              R. Blanchette / Global Director, SDE
Supplier APQP: Open Issues - Corrective Action Plan
  Supplier Name:        0                                                 Component Manufacturing Location:     0                                     Supplier Code:        0

  TRW Part Numbe(s):                                                                                                                                  Issued by:

  Customer Name:                                           Customer Platform:                                 TRW 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




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




Distribution:




  Date: 16 Jan 2008                                                                       Open Issues                                                                         Process Owner/Department:
  Revision: D                                                                                                                                                          R. Spariosu / Supplier Development
  Doc No.: D_020_4_03                                                                                                                                                                         Approved by:
  Page 25 of 26                                                                                                                                                        R. Blanchette / Global Director, SDE
                                                                                       Part Number

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

Function                                                         Function                                               Supplier
                    Name                                                    Name
                    Dept.                                                   Dept.
                    Tel.                                                    Tel.
  TRW Purchasing
  Commodity Mgr
                    Fax.                                                    Fax.
                    E-mail                                                  E-mail
                    Adress/                                                 Adress/
                    Location                                                Location
                    Name                                                    Name
                    Dept.                                                   Dept.
                    Tel.                                                    Tel.
  TRW Purchasing
 Product Line Mgr
                    Fax.                                                    Fax.
                    E-mail                                                  E-mail
                    Adress/                                                 Adress/
                    Location                                                Location
                    Name                                                    Name
                    Dept.                                                   Dept.
   TRW Supplier     Tel.                                                    Tel.
   Development      Fax.                                                    Fax.
    Engineering     E-mail                                                  E-mail
                    Adress/                                                 Adress/
                    Location                                                Location
                    Name                                                    Name
                    Dept.                                                   Dept.
                    Tel.                                                    Tel.
 TRW Engineering Fax.                                                       Fax.
                    E-mail                                                  E-mail
                    Adress/                                                 Adress/
                    Location                                                Location
                    Name                                                    Name
                    Dept.                                                   Dept.
TRW Receiving Plant Tel.                                                    Tel.
     Logisitic &    Fax.                                                    Fax.
     Packaging      E-mail                                                  E-mail
                    Adress/                                                 Adress/
                    Location                                                Location
                    Name                                                    Name
                    Dept.                                                   Dept.
                    Tel.                                                    Tel.
TRW Receiving Plant
       Quality
                    Fax.                                                    Fax.
                    E-mail                                                  E-mail
                    Adress/                                                 Adress/
                    Location                                                Location
                    Name                                                    Name
                    Dept.                                                   Dept.
                    Tel.                                                    Tel.
Project management Fax.                                                     Fax.
                    E-mail                                                  E-mail
                    Adress/                                                 Adress/
                    Location                                                Location




     Date: 16 Jan 2008                                Contacts                                                                               Process Owner/Department:
     Revision: D                                                                                                                      R. Spariosu / Supplier Development
     Doc No.: D_020_4_03                                                                                                                                     Approved by:
     Page 26 of 26                                                                                                                    R. Blanchette / Global Director, SDE

				
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