Prototype Project Plan Data Warehouse by meu51305

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Prototype Project Plan Data Warehouse document sample

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									                                                                                                   Responsibility
  Meeting(s)                                             Process
                                                                                                CBxx         Supplier


                                             Award Business                                      X



                        Review Design For Manufacture & Prepare a "Design
  Pre-Meeting                                                                                                   X
                        Review Summary Sheet"


                        APQP Kick-Off Meeting
                        - Review Key Milestones
                        - Review Annual Volumes
                        - Supplier to Submit "Design Review
                          Summay Sheet" for Any Change Requests
  1st Meeting           - Joint Design Review                                                    X              X
                        - Review Critical Characteristics
                        - Review Statistical Evaluation Method to be
                          deployed
                        - Review Interface Points
                        - Document all Issues on Open Issue Sheet




                                                  Design
                                                 Change
                                                 Required
                   No


                                                   Yes

                                   Submit SCR for Approved Change(s)                                            X


                                               Raise CNPR                                        X


                            Drawing to be Revised & Resubmitted to Supplier                      X


                                     Review Design For Manufacture                                              X


                        - Complete Timeline for A1 - A8 APQP Check Sheets
                        - Prepare Preliminary PFMEA
  Pre-Meeting                                                                                                   X
                        - Design Gauge(s) for Critical features and Submit
                          Concept to PBR



                        APQP Meeting:
                        - Review Key Milestones (must include A1 - A8 Check
                          Sheet Timing)
                        - Supplier to Submit "Design Review Summay Sheet" for
 2nd Meeting              Any Change Requests (if applicable)                                                   X
                        - Joint Design Review (if applicable)
                        - Review Preliminary PFMEA (including mistake proofing)
                        - Review Gauge Concept/Drawings for Critical Features
                        - Review Open Issues
                                                                                          Yes


                                                  Design
                                                 Change
                                                 Required



                                                    No


                        APQP Meeting:
                        - Review Key Milestones (including A1 - A8 Check
                          Sheet Timing, Gauge and Tooling Status)
                        - Review Preliminary PFMEA (including mistake proofing)
  3rd Meeting                                                                                                   X
                        - Review Control Plan and Reaction Plan (as per PBR
                          Model Line)
                        - Review Final Gauge Design for Critical Features
                        - Review Open Issues




                        APQP Meeting:
                        - Review Key Milestones (including A1 - A8 Check
                          Sheet Timing, Gauge and Tooling Status)
4th Meeting Etc.        - Review Preliminary PFMEA (including mistake proofing)                                 X
                        - Review Control Plan and Reaction Plan (as per PBR
                          Model Line)
                        - Review Open Issues



                   No
                                                  All Open
                                               Issues Closed



                                                   Yes

                                            Gateway Sign-Off                                     X


                                                  PPAP                                                          X


                                               Run @ Rate                                                       X




                                               d33027eb-26a3-41e8-b164-48e51f04d5f6.xls                                 Page 1
                                                                       Key Project Milestones
                   Project Manager                                    Customer                      Model/Year                  Product Name                         Part Number




                        YEAR                                        2004                     2005                    2006                      2007                       2008

                  Annual Volume(s)

        Supplier Quoted Annual Capacity

Issue /                                                 Supplied
        List of Technical Specifications                  (Y/N)
 Date                                                                                                                COMMENTS

          WIG 11-001
          MS1131




                                                                                                                TIMING
  Qty             Customer Key Milestones                Date                2003                    2004                    2005                    2006
                                                                   J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D

          Prototype Build @ CBxx
          Pilot Build @ CBxx
          PPAP @ CBxx
          Run @ Rate @ CBxx
          SOP @ CBxx
          SOP @ Customer
                                                                                                                TIMING
  Qty              Supplier Key Milestones               Date                2003                    2004                    2005                    2006
                                                                   J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D

          New/Refurbished Prototype Tooling
          Prototype PPAP @ Supplier
          New/Refurbished Production Tooling
          Production Gauge(s)
          Packaging Review
          Pilot Run @ Supplier
          Packaging Transit Trials
          Statistical Evaluation of Critical Features
          PPAP/Certification @ Sub-Supplier
          PPAP @ Supplier
          Run @ Rate @ Supplier
          SOP @ Supplier
                                                                                                                TIMING
     Supplier APQP Milestones (A1 - A8)                  Date                2003                    2004                    2005                    2006
                                                                   J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
DFMEA (A1 Check Sheet)
- If applicable
Feasibility Review
 - Design
   - Prototype
   - Capability & Readiness
Design Information (A2 Check Sheet)
- If applicable
New Equipment, Tooling & Test Equipment (A3
Check Sheet)
Tooling Plan
Equipment/Machinery Plan
Gauge Review:
   - Design
   - Build
   - Measurement System R&R
Product/Process Quality (A4 Check Sheet)
Floor Plan (A5 Check Sheet)
Process Flow Chart (A6 Chech Sheet)
   - Preliminary
   - Prototype
   - Pre-Launch
   - Production
Process FMEA (A7 Chech Sheet)
   - Preliminary
   - Prototype
   - Production
  - RPN Reduction Plans
Control Plan (A8 Check Sheet)
   - Preliminary
   - Prototype
   - Pre-Launch
   - Production
                             Ledged                                                                                                                                   1                  1

          On Time

          May Impact Timing
          Late                                                                                                   <<- DATELINE ->>

GATEWAY SIGN-OFF
                                                                       Supplier Development Manager/Engineer                        Signature                               Date




                                                                                           Page 2                                                 d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                             Supplier Quality APQP Project Contact List

Supplier Code                                        Manufacturing Address


Supplier Name




         Supplier Contacts         Name                            E-Mail Address                      Contact Numbers




           CBxx Contacts           Name                            E-Mail Address                      Contact Numbers




                                                 Page 3                             d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                    Initial Risk Evaluation Checklist
                                                                              Risk Level
 Item                                   Questions                               High                              Comments
                                                                               Medium
                                                                                Low
         DESIGN CATEGORY
   1     - New Commodity For Selected Supplier? (RISK DRIVER*)
   2     - New Materials or Technology? (RISK DRIVER*)
   3     - New/Different Application of a Carry-Over Part? (RISK DRIVER*)
   4     - New Design Concept?
   5     - Are there Safety/Emissions/Noise Requirements?
   6     - Offshore Engineering Site?
   7     - Will Design Need To Be Coordinated With Mating
           Parts For Fit, Function, or Appearance?
    8    - Are There Other Car Line Applications Planned?
    9    - Any Historic Quality/Warranty Issues?
   10    - Is Program Timing An Issue?
   11    - Are Sample Submission Dates Too Late for MTS's?
         MANUFACTURING CATEGORY
   12    - New Manufacturing Facility? (RISK DRIVER*)
   13    - Is This a New Manufacturing Process? (RISK DRIVER*)
   14    - A Part or System With Historical Launch Problems? (RISK DRIVER*)
   15    - Offshore Manufacturing Site?
   16    - Will Supplier Need Source Evaluation?
   17    - Is New Production Equipment Required?
   18    - Are Special Tools or Tooling Fixtures Required?
   19    - Are Gages or Check Fixtures Required to Ensure Dimensional
   20    - Any Potential Handling or Shipping Issues?
         - Will Parts Ever Be Shipped From a Location other than the
   21
           Primary Source (i.e. Warehouse, Offshore, etc.)
   22    - Will Returnable Packaging Be Required?
   23    - Is JIT Delivery or Sequenced Part Delivery Required?
         ASSEMBLY CATEGORY
   24    - Is Part Installation an Issue?
   25    - Are Special Tools/Fixtures Required to Install Part in Vehicle?
         SERVICE CATEGORY
   26    - Is Part Serviceability a Problem?
   27    - Are Special Tools/Fixtures Required?
         OTHER CATEGORY
   28    - Other?
   29    - Other?

NOTE: * INDICATES RISK DRIVER - PROCESS SPECIALIST ASSISTANCE MAY BE REQUIRED

Initial Risk Evaluation Summary

         INITIAL RISK EVALUATION RATING (Select One Below)
                 (Refer to Initial Risk Evaluation Checklist)

         LOW LEVEL OF CONCERN                             INITIAL RISK EVALUATION TEAM INDICATES A LOW LEVEL OF
                                                          CONCERN REGARDING THE SUCCESS OF SUPPLYING THIS PRODUCT.


         MEDIUM LEVEL OF CONCERN                          INITIAL RISK EVALUATION TEAM INDICATES THAT THERE IS A MEDIUM
                                                          LEVEL OF CONCERN REGARDING ONE OR MORE CATEGORIES
                                                          ASSURING THE SUCCESS OF SUPPLYING THIS PRODUCT.

         HIGH LEVEL OF CONCERN                            INITIAL RISK EVALUATION TEAM INDICATES THAT THERE IS A HIGH
                                                          LEVEL OF CONCERN REGARDING ONE OR MORE CATEGORIES, (OR
                                                          ONE OR MORE RISK DRIVERS) ASSURING THE SUCCESS OF
                                                          SUPPLYING THIS PRODUCT.

LIST HIGH CONCERN ITEMS




LIST MEDIUM CONCERN ITEMS




                                                                              Page 4                  d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                           Program Review Checklist

The purpose of this meeting is to develop a common understanding between our companies concerning the total
requirements of the part/material.

Program Kickoff
   1. Does the supplier understand the immediate application and intended end use of the part/material?
 Yes              No                  Specify
                                                                                                                        .

   2
          a. Does the supplier understand Special Characteristics (SC) dimensions with respect to CBxx's mating parts,
function, and manufacturing processes?                  Yes                    No
Specify plans to gain understanding:
                                                                                                                  .
          b. Does the supplier understand the critical nature of dimensions that interface with the customer's
application of their mating parts? List any known interfaces with the customer's parts:




        c. All customer interface features and/or dimensions must be monitored through the Process
Control Plan and should be reviewed for the application of Error Proofing techniques. Has CBxx
Engineering reviewed these interface dimensions for the application of SCs?
 Yes                No

          d. Have the right SCs been identified to control Critical Characteristics in order to prevent future
quality problems (SCAR's)?          Yes                  No



   b. Explain any quality concerns found during the prototype experience with the part or manufacturing process:



                                                                                                                        .
            Does the supplier understand the prototype requirements per WIG 11-001 procedure.
             Yes               No             Specify plans to gain understanding:
                                                                                                                        .

   3. Does the supplier understand their responsibility to control their suppliers (eg; platers, heat treaters,
      coaters, etc), including part approval process and quality control?            Yes                 No
      Explain how this requirement will be met:
                                                                                                                        .

   4 What is the supplier's quoted 5-day capacity?
       a. What production quantities are estimated for the future years?

                                                    Model Year                         Required Volume



            High Volume Scenario:

         b. What is the planned Tooled Capacity at SOP?                                    .     Does it support the high


                                                        Page 5           d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
            volume scenario?         Yes              No                    If No, specify action plans:
                                                                                                                  .



   5 Is a Value Engineering, Error-Proofing, Design For Manufacturing & Assembly, or other
workshops applicable?         Yes              No
Explain opportunity and possible dates:
                                                                                                                  .


    6 Has a concept pack per the CBxx packaging specification been developed?
  Yes                 No               If Yes, specify:                                                           .
If No, specify plans for completion:                                                                              .
       Is the concept of returnable containers appropriate for this application?
       Yes                 No                                                    (M.E.) and
       (buyer) will assist the suppliers in defining the program.
       Specify any special packaging concepts:

                                                                                                                  .



   7. CBxx requires the use of accredited laboratories for PPAP submission of data for
specified characteristics.

      Which characteristics will require accredited laboratory documentation? Specify:
                                                                                                                  .
      Explain plan for the supplier to meet the above requirements:
                  Their lab is already accredited by:                                                      .
                  They will use an outside accredited lab:                                                 .
                  Other:                                                                                   .

                 *Note: Third party registration to QS-9000 or ISO Guideline 025 is acceptable
      Does the supplier understand that the Laboratory's "Scope of Accreditation" must be included with the
      PPAP submission?        Yes               No

   8 CBxx requires 1.67 Ppk minimum (short-term) process capability and 1.33 Cpk
     minimum (long-term) process performance on special characteristics
     (Refer to the AIAG SPC and PPAP manuals.) All characteristics must conform
     100% to specifications for the life of the part/material.

            Are there any print, material specifications or Process Control Plan changes needed to meet
            these requirements?      Yes                 No                  Explain:
                                                                                                                  .

   9. Supplier submission of Material for Production Approval (PPAP):
                       samples per:                  cavity     (total # cavities                     )
                                                     mold       (total # molds                        )
                                                     other:                              (total # other           )
           are required by                           for PPAP Level 3.

  10. Does the supplier understand that PPAP approval status is Engineering Change Level specific, cavity
specific, and process specific?
 Yes

  11. The default level for PPAP submissions is Level 3. The default for Raw Material PPAP submissions
is Level 4. Consult the AIAG PPAP manual for details. Additionally, CBxxI requires a copy of the
Hazardous Material and Restricted and Reportable Chemicals Form with the appropriate pre-approval


                                                       Page 6          d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
signatures to be attached to all PPAP submissions.

PPAP Submission Level (if other than default):

 12. Does the supplier completely understand the requirements of the PPAP submission, resubmission
     procedures in the event submission is not given full approval, and the shipping of PPAP submission
     and parts/material?     Yes
     PPAP shipping location:
                                                                                                                  .

 13. Does the supplier understand that it is their responsibility to resubmit any Interim approved parts prior
     to the expiration date (preferably 2 weeks prior to allow our plants time to process)?
      Yes                 No

 14. Production Part Approval is always required prior to the first production shipment. Does the supplier
     understand the situations where PPAP submissions are required due to future product or process
     changes? (See the AIAG Manual)
      Yes               No

 15.
  a.       Does the receiving plant need a trial run for approval?     Yes                No
           Specify the program with assignments and dates. Designate persons for follow-up to assure
           completion:
                                                                                                                  .

           Due date:
           Quantity Needed:
           Supplier Promised Delivery Date:
           Instructions for trial run delivery:



   b. The most common problems with any parts are: 1) missed operations, 2) mixed parts, 3) surface
imperfections, and 4) other visual non-conformances. Explain the procedures the supplier will use to
prevent these potential quality problems:

                                                                                                                  .

 16. HAZARDOUS MATERIAL - Is a Material Safety Data Sheet required? Examples of materials
     requiring MSDS include but are not limited to: oils, lubricants, cleaners, adhesives, aerosol sprays, etc.
      Yes               No
           Does the supplier understand this requirement?             Yes               No
           Document below who will complete the form, to whom it is to be sent, and the due date.




 17. Early Production Containment
       a. Is the Early Production Containment plan adequate?             Yes               No
     Specify plan for completion:                                                                                 .
                 Note: The early production containment plan is synonymous to the Pre-Launch
                 Control Plan as described by the APQP Manual.

        b. Does the supplier understand when Early Production Containment Applies?
       Yes             No              Specify plans to gain understanding:
                                                                                                                  .

        c. Does the supplier understand the Early Production Containment exit criteria?
       Yes             No              Specify plans to gain understanding:

                                                       Page 7          d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                                                                                   .

         d. What is the Early Production Containment quantity or duration?
                                                                                     .
 18. Upon successful completion of Early Production Containment, all suppliers are required to
measure their quality performance and work for continuous improvement of all processes and parts.
                Does the supplier fully understand the requirements of Continuous Improvement?
                  Yes               No              Explain action to comply:
                                                                                                                   .

 19. Under what authority does the supplier need to ship production parts to the CBxx facility?
Default is PPAP Full Approval                .

If not under full PPAP approval, state Interim Level and reasons for Interim.
PPAP Interim Approval                      , Expiration Date:                    .
Other                               , Expiration Date:                      Specify action plans:
                                                                                                                   .

  20. A "Run At Rate" study will be required to assure all systems are in place and adequate.
(Complete Floor Plan Checklist A-5 prior to run at rate.) Does the supplier understand that they must
be able to run at Tooled Capacity at the time of the Run At Rate?                  Yes              No


  21. Will the Run At Rate study be a customer monitored R @ R?
  Yes                No               If Yes, specify date the supplier can accommodate such study:
If No, specify date the supplier will fax the Self-Monitored Run at Rate study form:

  22. Have Run at Rate studies and capacity issues been reviewed with sub-suppliers?
 Yes                  No               It is strongly recommended that the supplier review these issues with
their suppliers prior to start of production.

 23. Are there tooling, material, equipment, etc., problems that would jeopardize the estimated production
quantities? Yes                No                  Specify:                                                        .

 24. Part or Division Specific questions (optional per division)?
       1.

         2.

         3.




                                                        Page 8          d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                           TEAM FEASIBILITY COMMITMENT
Customer:                                                             Date:

Part Number:                                       Part Name:

Feasibility Considerations
Our product quality planning team has considered the following questions, not intended to be all-inclusive in
performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for
analyzing the ability to meet all specified requirements. All "no" answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the specified requirements.

           YES    NO                                   CONSIDERATION
                         Is product adequately defined (application requirements, etc. to enable
                         feasibility evaluation?
                         Can Engineering Performance Specifications be met as written?
                         Can product be manufactured to tolerances specified on drawing?
                         Can product be manufactured with Cpk's that meet requirements?
                         Is there adequate capacity to produce product?
                         Does the design allow the use of efficient material handling techniques?
                         Can the product be manufactured without incurring any unusual:
                                         - Costs for capital equipment?
                                         - Costs for tooling?
                                         - Alternative manufacturing methods?
                         Is statistical process control required on the product?
                         Is statistical process control presently used on similar products?
                         Where statistical process control is used on similar products:
                                         - Are the processes in control and stable?
                                         - Are Cpk's greater than 1.33?

Conclusion

        Feasible         Product can be produced as specified with no revisions.
        Feasible         Changes recommended (see attached).
        Not Feasible     Design revision required to produce product within the specified requirements.

Sign-Off


Team Member/Title/Date                                          Team Member/Title/Date



Team Member/Title/Date                                          Team Member/Title/Date



Team Member/Title/Date                                          Team Member/Title/Date




                                                    Page 9          d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                    Special Characterists & CBxx/Customer Interface Point
                                                                                                           PPAP

                                     Grid              Supplier Gauge Drawing                             Statistical
 Item     Feature / Dimension                                                                Guage
                                   Reference             Number Reference                                 Evaluation Statistical
                                                                                             R&R
                                                                                                         of Process      Method
                                                                                            Required
                                                                                                           Required
The Important Quality Items and Specifications, for this part are listed below. The Supplier shall exercise full process control as per this inspection standa
Capabilty data to be available for all items with a mark in the SPC column




                                                                         Page 10           d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                                                                                                                                FG 11-010 (Current Issue 4)
                                                                           Supplier APQP Open Issues
                    Supplier/Mfg Location:                                                                Part Number:                                                      Issue No.
                          Supplier Contact:                                                                Program(s):
                               SDE Contact:                                                                 Part Name:
                               Meeting Date:                                                              Next Meeting:

            Number of Issues                                                                       Number of Issues
                                                      A1 - A4 Checklist Status                                                                   A5 - A8 Checklist Status
            High         Medium                                                                    High       Medium
             0             0         A-1 Design FMEA Checklist                                      0           0         A-5 Floor Plan Checklist
 Status




             0             0         A-2 Design Information Checklist                               0           0         A-6 Process Flow Chart Checklist
             0             0         A-3 New Equipment, Tooling and Test Equipment Checklist        0           0         A-7 Process FMEA Checklist
             0             0         A-4 Product/Process Quality                                    0           0         A-8 Control Plan Checklist
                                          *Type Key:                                                              % Status
 Legend




          S = Design-Supplier                  T = Tooling       M = Manufacturing/Process                    25% Issue Identified
          E = Design-CBxx                      C = Capacity      P = Purchasing                               50% Action Plan Proposed
          F = Facilities/Equipment             G = Gauging       PK = Packaging                               75% Action Plan Implemented
          Q = Quality                          O = Other :____________________________                        100% Issue Resolved
                         Priority                                                                                               Action Plan                                 Revised
Item        Issue                                        Issues                     Responsible                                                                 Promise                   %
                          High                                                                    * Type                             &                                      Promise
 No.         Date        Medium                Description and/or Sketch              Person                                                                     Date                   Status
                                                                                                                              Progress to Plan                               Date
                          Low




                                                                                               Page 11                                  d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                     *Type Key:                                                           % Status
 Legend   S = Design-Supplier             T = Tooling       M = Manufacturing/Process                 25% Issue Identified
          E = Design-CBxx                 C = Capacity      P = Purchasing                            50% Action Plan Proposed
          F = Facilities/Equipment        G = Gauging       PK = Packaging                            75% Action Plan Implemented
          Q = Quality                     O = Other :____________________________                     100% Issue Resolved
                         Priority                                                                                      Action Plan                               Revised
Item        Issue                                  Issues                      Responsible                                                            Promise                %
                          High                                                               * Type                         &                                    Promise
 No.         Date        Medium          Description and/or Sketch               Person                                                                Date                Status
                                                                                                                     Progress to Plan                             Date
                          Low




                                                                                         Page 12                                d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                     LESSONS LEARNT / ACTION PLAN
                                                                                                                                   Quality System /
                                                                                                                Mistake Proofing
                            Issue From Previous                                                  FMEA Updated                      Documentation                   Date
Model   Issue   Process                                Action Plan   Responsibility   Comments                    Employed?                           Date Due
                          Launches\Quality Concern                                                 (Yes/No)                           Revised                    Complete
                                                                                                                    (Yes/No)
                                                                                                                                      (Yes/No)




                                                                        Page 13                                  d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                     LESSONS LEARNT / ACTION PLAN
                                                                                                                                   Quality System /
                                                                                                                Mistake Proofing
                            Issue From Previous                                                  FMEA Updated                      Documentation                   Date
Model   Issue   Process                                Action Plan   Responsibility   Comments                    Employed?                           Date Due
                          Launches\Quality Concern                                                 (Yes/No)                           Revised                    Complete
                                                                                                                    (Yes/No)
                                                                                                                                      (Yes/No)




                                                                        Page 14                                  d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                                                                          Part Number:                  0
                                                                                                                              Red Count           0
A-1 DESIGN FMEA CHECKLIST                                                                                                    Yellow Count         0
                                                                                  Status
                    Question / Part Number                               Yes No    High     Comments / Actions               Responsibility     Timing
                                                                                  Medium
                                                                                   Low
    Was the SFMEA and/or DFMEA prepared using the
1   DaimlerChrysler, Ford, and General Motors Potential Failure
    Mode and Effects Analysis (FMEA) reference manual?

2   Have historical campaign and warranty data been reviewed?
3   Have similar part DFMEAs been considered?
    Does the SFMEA and/or DFMEA identify Special
4
    Characteristics?
    Have design characteristics that affect high risk priority failure
5
    modes been identified?
    Have appropriate corrective actions been assigned to high risk
6
    priority numbers?
    Have appropriate corrective actions been assigned to high
7
    severity numbers?
    Have risk priorities been revised when corrective actions have
8
    been completed and verified?




                                                                                  Page 15            d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                                                                          Part Number:                  0
                                                                                                                              Red Count           0
A-2 DESIGN INFORMATION CHECKLIST                                                                                             Yellow Count         0
                                                                                  Status
                     Question / Part Number                            Yes   No    High     Comments / Actions               Responsibility     Timing
                                                                                  Medium
                                                                                   Low
     A. General
     Does the design require:
1    > New materials?                                /
2    > Special tooling?                           /
3    Has assembly build variation analysis been considered?
4    Has Design of Experiments been considered?
5    Is there a plan for prototypes in place?                     /
6    Has a DFMEA been completed?                              /
 7   Has a DFMA been completed?
 8   Have service and maintenance issues been considered?
 9   Has the Design Verification Plan been considered?
10   If yes, was it completed by a cross functional team?
11   Are all specified tests, methods, equipment and acceptance
     criteria clearly defined and understood?
12   Have Special Characteristics been selected?
     /
13   Is bill of material complete?                               /
14   Are Special Characteristics properly documented?
     B. Engineering Drawings
15   Have dimensions that affect fit, function and durability been
     identified?
16   Are reference dimensions identified to minimize inspection
     layout time?
17   Are sufficient control points and datum surfaces identified to
     design functional gages?
18   Are tolerances compatible with accepted manufacturing
     standards?
19   Are there any requirements specified that cannot be evaluated
     using known inspection techniques?
     C. Engineering Performance Specifications
20   Have all special characteristics been identified?             /
21   Is test loading sufficient to provide all conditions, i.e.,
     production validation and end use?
22   Have parts manufactured at minimum and maximum
     specifications been tested?




                                                                                  Page 16            d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                                                                            Part Number:                  0
                                                                                                                                Red Count           0
A-2 DESIGN INFORMATION CHECKLIST                                                                                               Yellow Count         0
                                                                                    Status
                     Question / Part Number                              Yes   No    High     Comments / Actions               Responsibility     Timing
                                                                                    Medium
                                                                                     Low
23 Can additional samples be tested when a reaction plan
   requires it, and still conduct regularly scheduled in-process
   tests?
24 Will all product testing be done in-house?                    /

25 If not, is it done by an approved subcontractor?
   /
26 Is the specified test sampling size and/or frequency feasible?

27 If required, has customer approval been obtained for test
   equipment?
   D. Material Specification
28 Are special material characteristics identified?                  /

29 Are specified materials, heat treat and surface treatments
   compatible with the durability requirements in the identified
   environment?
30 Are the intended material suppliers on the customer approved
   list?
31 Will material suppliers be required to provide certification with
   each shipment?
32 Have material characteristics requiring inspection been
   identified?                      If so,
33 > Will characteristics be checked in-house?                     /

34 > Is test equipment available?                          /
35 > Will training be required to assure accurate test results?
36 Will outside laboratories be used?                        /
37 Are all laboratories used accredited (if required)?         /
   Have the following material requirements been considered:
38 > Handling?                                         /
39 > Storage?                                            /
40 > Environmental?                                     /




                                                                                    Page 17            d33027eb-26a3-41e8-b164-48e51f04d5f6.xls
                                                                                                      Part Number:                   0
                                                                                                                            Red Count          0
A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST                                                                   Yellow Count        0
                                                                              Status
                    Question / Part Number                           Yes No    High      Comments / Actions               Responsibility   Timing
                                                                              Medium
                                                                               Low
   Does the design require:
1  > New materials?                                    /
2  > Quick change?                                  /
3  > Volume fluctuations?                               /
4  > Mistake proofing?                                  /
   Have lists been prepared identifying:
 5 > New equipment?                                    /
 6 > New tooling?                                    /
 7 > New test equipment?                               /
   Has acceptance criteria been agreed upon for:
 8 > New equipment?                                      /
 9 > New tooling?                                    /
10 > New test equipment?                               /
11 Will a preliminary capability study be conducted at the tooling
   and/or equipment manufacturer?
12 Has test equipment feasibility and accuracy been established?

13 Is a preventive maintenance plan complete for equipment and
   tooling?
14 Are setup instructions for new equipment and tooling complete
   and understandable?
15 Will capable gages be available to run preliminary process
   capability studies at the equipment supplier's facility?
16 Will preliminary process capability studies be run at the
   processing plant?
17 Have process characteristics that affect special product
   characteristics been identified?
18 Were special product characteristics used in determining
   acceptance criteria?
19 Does the manufacturing equipment have sufficient capacity to
   handle forecasted production and service volumes?
20 Is testing capacity sufficient to provide adequate testing?




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A-4 PRODUCT / PROCESS QUALITY CHECKLIST                                                                                           Yellow Count        0
                                                                                     Status
                      Question / Part Number                                Yes No    High      Comments / Actions               Responsibility   Timing
                                                                                     Medium
                                                                                      Low
1    Is the assistance of the customer's quality assurance or
     product engineering activity needed to develop or concur to the
     control plan?
2    Has the supplier identified who will be the quality liaison with
     the customer?
3    Has the supplier identified who will be the quality liaison with its
     suppliers?
4    Has the quality assurance system been reviewed using the
     Chrysler, Ford, and General Motors Quality System
     Assessment?
     Are there sufficient personnel identified to cover:
5    > Control plan requirements?                             /
6    > Layout inspection?                                 /
7    > Engineering performance testing?                        /
8    > Problem resolution analysis?                         /
     Is there a documented training program that:
 9   > Includes all employees?                             /
10   > Lists whose been trained?                             /
11   > Provides a training schedule?                          /
     Has training been completed for:
12   > Statistical process control?                       /
13   > Capability studies?                                /
14   > Problem solving?                                    /
15   > Mistake proofing?                                   /
16   > Other topics as identified?                           /
17   Is each operation provided with process instructions that are
     keyed to the control plan?
18   Are standard operator instructions available at each operation?

19 Were operator/team leaders involved in developing standard
   operator instructions?
   Do inspection instructions include:
20 > Easily understood engineering performance specifications?

21   > Test frequencies?                                    /
22   > Sample sizes?                                      /
23   > Reaction plans?                                     /
24   > Documentation?                                     /


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                                                                                                      Part Number:                   0
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A-4 PRODUCT / PROCESS QUALITY CHECKLIST                                                                                    Yellow Count        0
                                                                              Status
                     Question / Part Number                          Yes No    High      Comments / Actions               Responsibility   Timing
                                                                              Medium
                                                                               Low
     Are visual aids:
25   > Easily understood?                                  /
26   > Available?                                       /
27   > Accessible?                                   /
28   > Approved?                                         /
29   > Dated and current?                                  /
30   Is there a procedure to implement, maintain, and establish
     reaction plans for statistical control charts?
31   Is there an effective root cause analysis system in place?
32   Have provisions been made to place the latest drawings and
     specifications at the point of the inspection?
33   Are forms/logs available for appropriate personnel to record
     inspection results?
     Have provisions been made to place the following at the
     monitored operation:
34   > Inspection gages?                                 /
35   > Gage instructions?                                /
36   > Reference samples?                                /
37   > Inspection logs?                              /
38   Have provisions been made to certify and routinely calibrate
     gages and test equipment?
     Have required measurement system capability studies been:

39 > Completed?                                             /
40 > Acceptable?                                          /
41 Are layout inspection equipment and facilities adequate to
   provide initial and ongoing layout of all details and
   components?
   Is there a procedure for controlling incoming product that
   identifies:
42 > Characteristics to be inspected?                         /
43 > Frequency of inspection?                           /
44 > Sample size?                                     /
45 > Designated location for approved product?                  /
46 > Disposition of nonconforming products?                      /
47 Is there a procedure to identify, segregate, and control
   nonconforming products to prevent shipment?
48 Are rework/repair procedures available?


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A-4 PRODUCT / PROCESS QUALITY CHECKLIST                                                                                  Yellow Count        0
                                                                            Status
                    Question / Part Number                         Yes No    High      Comments / Actions               Responsibility   Timing
                                                                            Medium
                                                                             Low
49 Is there a procedure to requalify repaired/reworked material?

50 Is there an appropriate lot traceability procedure?
51 Are periodic audits of outgoing products planned and
   implemented?
52 Are periodic surveys of the quality system planned and
   implemented?
53 Has the customer approved the packaging specification?




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A-5 FLOOR PLAN CHECKLIST                                                                                                    Yellow Count         0
                                                                                 Status
                     Question / Part Number                             Yes No    High     Comments / Actions              Responsibility      Timing
                                                                                 Medium
                                                                                  Low
1    Does the floor plan identify all required process and inspection
     points?
2    Have clearly marked areas for all material, tools, and
     equipment at each operation been considered?
3    Has sufficient space been allocated for all equipment?
     Are process and inspection areas:
4    > Of adequate size?                               /
5    > Properly lighted?                                /
6    Do inspection areas contain necessary equipment and files?

     Are there adequate:
7    > Staging areas?                                  /
8    > Impound areas?                                  /
9    Are inspection points logically located to prevent shipment of
     nonconforming products?
10   Have controls been established to eliminate the potential for an
     operation, including outside processing, to contaminate or mix
     similar products?
11   Is material protected from overhead or air handling systems
     contamination?
12   Have final audit facilities been provided?
13   Are controls adequate to prevent movement of nonconforming
     incoming material to storage or point of use?




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                                                                                                     Part Number:                   0
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A-6 PROCESS FLOW CHECKLIST                                                                                                Yellow Count        0
                                                                             Status
                   Question / Part Number                           Yes No    High      Comments / Actions               Responsibility   Timing
                                                                             Medium
                                                                              Low
1   Does the flow chart illustrate the sequence of production and
    inspection stations?
2   Were all appropriate FMEA's (SFMEA, DFMEA) available and
    used as aids to develop the process flow chart?
3   Is the flow chart keyed to product and process checks in the
    control plan?
4   Does the flow chart describe how the product will move, i.e.,
    roller conveyor, slide containers, etc.?
5   Has the pull system/optimization been considered for this
    process?
6   Have provisions been made to identify and inspect reworked
    product before being used?
7   Have potential quality problems due to handling and outside
    processing been identified and corrected?




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A-7 PROCESS FMEA CHECKLIST                                                                                                Yellow Count         0
                                                                               Status
                    Question / Part Number                            Yes No    High     Comments / Actions              Responsibility      Timing
                                                                               Medium
                                                                                Low
1    Was the Process FMEA prepared using the Chrysler, Ford,
     and General Motors guidelines?
2    Have all operations affecting fit, function, durability,
     governmental regulations and safety been identified and listed
     sequentially?
3    Were similar part FMEA's considered?
4    Have historical campaign and warranty data been reviewed?

5    Have appropriate corrective actions been planned or taken for
     high risk priority items?
6    Have appropriate corrective actions been planned or taken for
     high severity numbers?
7    Were risk priorities numbers revised when corrective action
     was completed?
8    Were high severity numbers revised when a design change
     was completed?
9    Do the effects consider the customer in terms of the
     subsequent operation, assembly, and product?
10   Was warranty information used as an aid in developing the
     Process FMEA?
11   Were customer plant problems used as an aid in developing
     the Process FMEA?
12   Have the causes been described in terms of something that
     can be fixed or controlled?
13   Where detection is the major factor, have provisions been
     made to control the cause prior to the next operation?




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A-8 CONTROL PLAN CHECKLIST                                                                                                Yellow Count         0
                                                                               Status
                    Question / Part Number                            Yes No    High     Comments / Actions              Responsibility      Timing
                                                                               Medium
                                                                                Low
1   Was the control plan methodology referenced in Section 6
    used in preparing the control plan?
2   Have all known customer complaints been identified to
    facilitate the selection of special product/process
    characteristics?
3   Are all special product/process characteristics included in the
    control plan?
4   Were SFMEA, DFMEA, and PFMEA used to prepare the
    control plan?
5   Are material specifications requiring inspection identified?
6   Does the control pan address incoming (material/components)
    through processing/assembly including packaging?

7   Are engineering performance testing requirements identified?

8  Are gages and test equipment available as required by the
   control plan?
 9 If required, has the customer approved the control plan?
10 Are gage methods compatible between supplier and
   customer?




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