ADVANCED PRODUCT QUALITY PLANNING (APQP)
Scope:
The following procedure will be carried out in below conditions
1. Any Similar part which has not produced earlier
2. Any Similar part which has produced earlier
3. Existing Product ECN /PCN
4. Plant location Change.
5. If part is from Automotive Customer
• Entire Procedure of product development is carried out as per guidelines provided in the AIAG Reference Manual: APQP (2nd Edition)
• The activity to be done with respect to respective responsible person are defined in APQP Matrix.
• APQP Timing plan shall be made based on category defined in APQP Matrix
• APQP Timing plan shall be made based on category defined in APQP Responsibility Matrix
• Review Frequency: CFT: Every 15 days
Top Management along with CFT: Monthly and at phase end. During those review customer milestones shall be discussed
• NPD Head will be over all responsible for implementation of the requirements given in this procedure. However specific responsibilities of various departments for implementation of this procedure of this procedure are defined hereunder.
Initiate Phase I i.e. Plan and Define
1. Receive customer enquiry / documents / sample / drawing.
2. Enter details in New Development Log Book/ECN Logbook.
3. Review customer documents& resolve technical issue with customer.
4. Use best practices & take benefit of TGR / TGW and Past Defect History Records.
5. Supplier Selection (Raw Material , Tooling , Instrument and Gauges requirement)
6. List of Equipment, Tooling, Instrument Required/Resource Planning
7. Perform Risk Analysis for the Project and Capture the same in Risk Analysis Sheet
8. Define customer requirements, including special characteristics & Do Feasibility Study with CFT.
9. Prepare Quotation, submit to customer & resolve commercial issues.
10. Follow up with customer if no response is received within a week.
Initiate Phase II i.e. Product Development
1. Receive Development Order from the customer/LOI.
2. Contract Review
3. Prepare APQP Timing Plan to be prepared and get approval of top management
4. Prepare Tool Development Plan.
5. Prepare Fixture Development Plan.
6. Prepare Instrument/Gauge and Testing Equipment Plan
Initiate Phase III i.e. Process Design & Development
1. Prepare Process Flow Chart.
2. CFT will Prepare PFMEA Matrix.
3. CFT will Prepare PFMEA.
4. Prepare Pre-launch Control Plan.
5. Prepare & display necessary Work Instructions Inspection Standards for each production stage.
6. Prepare Packing standard
7. Procurement of Material
8. Training to concerned person for trial run.
9. All the material should move with Blue route card.
10. Conduct T – 1 Trial Run
11. Submit IPP Report along with the samples
12. Receive Sample Approval report from Customer if
13. Follow up with customer for the same
14. Follow up with customer if no response is received within a week.
15. Conduct T-2, T-3…. Tn Trial Run, if required in case of any Customer Complaint.
16. Plan for MSA and SPC for the Parts
Initiate Phase IV i.e. Product and Process Validation
1. Training to concerned person for pilot Lot
2. Start producing the Pilot Lot / Initial Parts.
3. Perform Measurement System Analysis Process Capability Study as required.
4. Conduct Process Audit (To be carried in process in which CC is maintained.)
5. Check pilot lot as per the Pre-launch Control Plan& prepare Layout Inspection Report and prepare all PPAP document, including PSW.
6. Evaluation of Packing Standard
7. Submit pilot lot &PPAP documents to customer for approval.
8. Follow up with customer if no response is received within a week
Initiate Phase V i.e. Feedback Assessment & Corrective Action
The following procedure will be carried out in below conditions
1. Any Similar part which has not produced earlier
2. Any Similar part which has produced earlier
3. Existing Product ECN /PCN
4. Plant location Change.
5. If part is from Automotive Customer
• Entire Procedure of product development is carried out as per guidelines provided in the AIAG Reference Manual: APQP (2nd Edition)
• The activity to be done with respect to respective responsible person are defined in APQP Matrix.
• APQP Timing plan shall be made based on category defined in APQP Matrix
• APQP Timing plan shall be made based on category defined in APQP Responsibility Matrix
• Review Frequency: CFT: Every 15 days
Top Management along with CFT: Monthly and at phase end. During those review customer milestones shall be discussed
• NPD Head will be over all responsible for implementation of the requirements given in this procedure. However specific responsibilities of various departments for implementation of this procedure of this procedure are defined hereunder.
Initiate Phase I i.e. Plan and Define
1. Receive customer enquiry / documents / sample / drawing.
2. Enter details in New Development Log Book/ECN Logbook.
3. Review customer documents& resolve technical issue with customer.
4. Use best practices & take benefit of TGR / TGW and Past Defect History Records.
5. Supplier Selection (Raw Material , Tooling , Instrument and Gauges requirement)
6. List of Equipment, Tooling, Instrument Required/Resource Planning
7. Perform Risk Analysis for the Project and Capture the same in Risk Analysis Sheet
8. Define customer requirements, including special characteristics & Do Feasibility Study with CFT.
9. Prepare Quotation, submit to customer & resolve commercial issues.
10. Follow up with customer if no response is received within a week.
Initiate Phase II i.e. Product Development
1. Receive Development Order from the customer/LOI.
2. Contract Review
3. Prepare APQP Timing Plan to be prepared and get approval of top management
4. Prepare Tool Development Plan.
5. Prepare Fixture Development Plan.
6. Prepare Instrument/Gauge and Testing Equipment Plan
Initiate Phase III i.e. Process Design & Development
1. Prepare Process Flow Chart.
2. CFT will Prepare PFMEA Matrix.
3. CFT will Prepare PFMEA.
4. Prepare Pre-launch Control Plan.
5. Prepare & display necessary Work Instructions Inspection Standards for each production stage.
6. Prepare Packing standard
7. Procurement of Material
8. Training to concerned person for trial run.
9. All the material should move with Blue route card.
10. Conduct T – 1 Trial Run
11. Submit IPP Report along with the samples
12. Receive Sample Approval report from Customer if
13. Follow up with customer for the same
14. Follow up with customer if no response is received within a week.
15. Conduct T-2, T-3…. Tn Trial Run, if required in case of any Customer Complaint.
16. Plan for MSA and SPC for the Parts
Initiate Phase IV i.e. Product and Process Validation
1. Training to concerned person for pilot Lot
2. Start producing the Pilot Lot / Initial Parts.
3. Perform Measurement System Analysis Process Capability Study as required.
4. Conduct Process Audit (To be carried in process in which CC is maintained.)
5. Check pilot lot as per the Pre-launch Control Plan& prepare Layout Inspection Report and prepare all PPAP document, including PSW.
6. Evaluation of Packing Standard
7. Submit pilot lot &PPAP documents to customer for approval.
8. Follow up with customer if no response is received within a week
Initiate Phase V i.e. Feedback Assessment & Corrective Action
1. Receive Pilot Lot Approval Documents from customer & hand over to Quality.
2. Record all quality issues in PDCA Analysis Sheet faced In-house & at Customer End during Trials. Analysis to be done in CAPA sheet.
3. Prepare TGR / TGW.
4. Prepare APQP Sign Off after SOP at Customer end for Mass Production Sheet& hand over all documents to Production
5. Start Production under IPC & monitoring the production activities closely for each production lot.
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