ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS
Doc.No. : PR/ENGG/01 Rev.No. : 02 02 Rev. Rev. dt : 04. 04.007.20 7.2008 08 Page Page No. No. : 1 of 8
PURPOSE 1)
To define procedures for new process development ,
2)
To Develop a cost effective Process to meet Customer timing requirements.
3)
To direct company's resources to meet customer requirements
4)
To identify problems too early, so that late changes are avoided
SCOPE Applicable to new process development Applicable to significant process change & significant design modification modification (If new tooling required or supplied by customer) DEFINITIONS
The Cross functional functional Team for new Process Development and for design process changes is fixed . appointed through an IOM. Development Team will consist of the following functions at the minimum. Engineering
: Programme Manager
Quality Assurance
: Team Member
Production
: Team Leader ( CFT Leader)
Maintenance
: Team Member
Purchase
: Team Member
Marketing
: Team Member
Amtek group functions and Customer's Customer's Representative ( when required by Customer ) will be invited for CFT meeting as and when necessary The person to liaise with Customer Customer and to represent Customer in internal functions will also be identified . CFT Leader can can co-ordinate with with any other member member as and when necessary. As and when necessary , operator will be involved during development.( Ex. C.P. , W.I. )
Record 1)
APQP File
Prepared by
Approved by
Master copy
Controlled copy
ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS Primary
Secondary
Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 2 of 8
Process Owner : Engineering
. i . d R r g . t o k r . u n A p M P E Q M
PROCESS CHART
Related Document
Start
Receive New Product Enquiry with Drawing and or sample.
Enquiry register
Assign Request for Quotation No. to each Drawing and Update RFQ Tracking Sheet.
Quotation
Business decision to process enquiry
No
Regret offer
Yes Formation of CFT Team for project
Customer / product information & standards given for
CFT form
NO
Clarify with customer
Yes Refer TGW/TGR record of previous project, Product history for necessary proactive action
Prepare Preliminary BOM , Preliminary Process Flow Chart, Risk Analysis , Manufacturing Team Feasibility, Special Product and Process Characteristics Identified based on Drawing or CRT agreement, Feasibility Review, identify opportunity for Mistake proofing and Review for need of sub supplier
Process flow
A
Prepared by
Approved by
Master copy
Controlled copy
Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 3 of 8
ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS Primary
Secondary
Process Owner : Engineering
. i . d R r g . t o k r . u n A p M P E Q M
PROCESS CHART
Related Document
A
Send to Approval
Prepare " Product Costing Sheet", Tooling Costing Sheet.
Costing sheet
Approval Quote to Customer along with Standard Terms Conditions No Acceptable
Negotiate & Resolve with Customer.
Yes P.O/Tooling Order from Customer
APQP Review Meeting ( Gate 1) Prepare APQP Timing Plan & ensure for adherence.
Receive new drawings & Quality documents from customer
1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point Need of sub supplier
NO
Review for Clarification required from customer if any Discuss with customer & get clarification , resolve issue if any.
B
Prepared by
Approved by
Review Record
Part Drawing
List of customer drawing
YES
Review and check customer data as per check list(AAL/D/CH/01)
Review of DFMEA , Product history, Quality rating, Drawing Dimns. Clarifications..
P.O.
Check list Identify & development of sub supplier
Start APQP activity of sub supplier as per doc.no AAL/CFT/F/07 . ( Sub supplier APQP Gate Ways )
H
Master copy
Controlled copy
Doc.No.
ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS
: PR/ENGG/01
Rev.No. : 02 Rev. dt
: 04.07.2008
Page No. : 4 of 8 Primary
Secondary
Process Owner : Engineering B
. i . d R r g . t o k r . u n A p M P E Q M
H
Prepare Amtek Drawing
OK
Get approval from customer & maintain as a Master copy
Put controlled copy stamp & issue to concern dept.
Amtek Drawing Pass all drawing specification,signi ficant,characterist ics(CC,SC,PTC,HI C details to supplier for child part development
Sample submit to Amtek
Master copy drawing file
Issue Register
Prepare Simulation data for analysis
OK OK
REJ
Not Ok Make changes
CAD data for tooling
Release Tooling Design to concern
Track Five Gateway timing plan & Update GYR Status
Convey rejected points to sub supplier & take corrective action if any.
PPAP from subsupplier as per level 3 requirement.
K C
Prepared by
Approved by
Master copy
Controlled copy
ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS Primary
Secondary
Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 5 of 8
Process Owner : Engineering
. i . t d R r g A o . r u n . k p M P E Q M
PROCESS CHART
Related Document
C
Review New Equipment, Tooling & Facilities
Identify Special Characteristic
1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point
APQP Review Meeting ( Gate 2)
Special char. sheet
Any Prototype requirements ?
No Yes Develop Prototype Control Plan & Proto samples.
K
Use PPAP approved part from sub- supplier
Validation of samples for appearance & dimensional aspects ( reliability requirement, if any) & submit to customer. Customer approval
Prepare Process parameters sheet
Process Para. sheet
Review Process Flow Chart
Flow chart
D
Prepared by
Approved by
Master copy
Controlled copy
ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS Primary
d o r P
. R . r u M P
Secondary
i . t g A n . k E Q M
Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 6 of 8
Process Owner : Engineering PROCESS CHART
Related Document
D
Prepare floor plan
Floor plan
Review PFMEA
Develop Pre-launch / production Control Plan
Control plan
Develop process Quality instructions / Operator instructions
Work instruction
Sampling Trial for casting & machining ( if involved. )
Review Record
Make corrections if any.
Inspection by QA
APQP Review Meeting ( Gate 3)
Validation of samples (product & process) , confirm parts are meeting dimensional , functional (& reliability requirement, with sub supplier part if any) .
1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point
E
Prepared by
Approved by
Master copy
Controlled copy
ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS Primary
Secondary
. i . d R r g . t o k r . u n A P M P E Q M
Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 7 of 8
Process Owner : Engineering PROCESS CHART
Related Document
E
Lay out Inspection by QA
Any SPC
No
Yes Develop SPC study Plan
Spc study plan
No Are New MSA
Yes Develop MSA study Plan
MSA Plan
Any Production Trial requirements
Dimensional Verification Sample Submission to customer ( With sub supplier part if any ) APQP Review Meeting ( Gate 4)
F
Prepared by
Approved by
Validation record 1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red
Master copy
Controlled copy
ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS Primary
n g i s e D
. R . r u M P
Secondary
Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 8 of 8
Process Owner : Engineering
i . t g A n . k E Q M
PROCESS CHART
Related Document
F
Customer feedback Corrections if any. PPAP Submission with all applicable documents. (Default level 3 & min. 300 parts unless specified.) Product quality planning summary & sign-off
APQP Review Meeting ( Gate 5)
Track 5000 components or 3 months
PPAP File 1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point
supplies (whichever is earlier ) for any Concern
Any concerns
Sign off sheet
Review sheet
Prod. Record
No
Yes Develop, Track Action Plan & review FMEA for high RPN.
Control plan
Any improvement or modification in process after PPAP approval must inform to internal Quality for approval
ECN
Stop
Prepared by
Approved by
Master copy
Controlled copy
