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7 D 24-Jun-2013
Lead Customer/Program:
Cover
Process Owner / Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
GSQM
MANAGEMENT MESSAGE SUPPLIER REQUIREMENTS & SELECTION
APQP
PHASE 3 Product/Process Realization PHASE 4 Pre-PPAP
Identify TRW & Supplier team contacts/roles/responsibilities Communicate & initiate Key Supplier Metrics Initial supplier program plan and timing Conduct cross-functional component design review APQP requirements Equipment, tooling & gage design review Create APQP Progress Report Initiate Open Issues document Review Preliminary Capacity Study Review Manufacturing Feasibility
Preliminary Process Flow, PFMEA & Control Plan review Review Supplier DFMEA (when applicable) Create PCM; Identify subsupplier value chain Supplier master schedule review Review Key Supplier Metrics Update previous phase open issues/key documents
Supplier Packaging Requirements Analysis of process failures and effects Process Flow Chart Use PCM for Pre-Launch Control Plan Process Instructions Finalize process capability study plan Validation review of off-tool condition Floor plan layout Pre-qualify equipment / tooling / gauging at supplier Review Key Supplier Metrics Update previous phase open issues/key documents
Pre-Production Run
Finalize complete PPAP submission package Cross-functional Key Metrics review; OK to launch sign-off Launch Readiness Audit Confirmation of full volume Run at Rate Initiate Safe Launch Practice Final component packaging review Review Key Supplier Metrics Close out previous phase open issues/key documents
Process Capability Study Finalize PCM; Prepare for Safe Launch Finalize PFMEA and Control Plan Launch Readiness Audit; document in Key Metrics Supplier Ramp Plan Re-qualify equipment / tooling/ gauging at supplier Appearance Approval (when applicable) Supplier participates in Plant Readiness Review Review Key Supplier Metrics Update previous phase open issues/key documents
5 Phases
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
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.
Visually displays and compares the results of the Key Metrics reports generated during APQP-4 and/or APQP-5. Operational definitions for the twelve key metrics. Explains the metric and its method of calculation.
Reporting form for suppliers to track progress on all APQP deliverables. Embedded copies of the Component Design Review, Product Characterisitics Matrix, and Launch Readiness Audit. 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. An example of how a Supply Chain Map may appear for a typical metal component.
The PCM is used initially to define and determine appropriate controls for special characteristics, other process critical features and customer touch points. This tab is used to define the process at TRW's 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. The use of this tab is identical to the functionality define above, with the exception that this is used to document the remaining supply chain's, below the Tier II supplier, impact on the critical features.
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.
Table of Contents
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Spariosu / Global Director, SDE
Format to be used for a weekly summary of the inspection results from the Safe Launch Plan.
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. 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.
Contacts
Table of Contents
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Spariosu / Global Director, SDE
Aug-13
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 10 11 12 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Sep-13
13 14 15 16 17 18 19 20 21
OUTPUT 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 3.1 3.2 J BRACKET Design FMEA Preliminary Capacity Study reviewed Manufacturing Feasibility reviewed Component Design Review Key Supplier Metrics initiated Supplier Project timing plan Open Issues Action Plan created TPH,PIPS& TQH Product Characteristic Matrix initiated Process flow chart PFMEA Control Plan Key Supplier Metrics reviewed Measurement/ Testing equipment
1. Supplier Kick-Off
X X X X X X X X X X X X X X X X X X X
O O O O O O O O O O O O O O O O O O O O O O
Tooling
NOTCHING TOOL-1 NOTCHING TOOL-2 R246 BENDING TOOL NOTCHING TOOL-1 R292 BENDING TOOL NOTCHING TOOL-1 NOTCHING TOOL-1 PUNCHING TOOL BLANKING TOOL
COMPOUND TOOL
SUPPORT ANGLE FUEL TANK GUSSET FUEL TANK MTG BKT WASHER ASSEMBLY
X X X X X
O O O
3.3 3.4 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5.1 5.2 5.3
Capital equipment Training Process instructions Packaging Key Supplier Metrics reviewed ELV/IMDS Safe Launch Plan finalized Supplier Ramp Plan Plant Readiness Review Launch Readiness Audit Appearance Approval Process (when applicable) Key Supplier Metrics reviewed PPAP Launch Readiness Audit Run at Rate
4. Pre-PPAP
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6. Other Requirements
KEY:
X Planned start
MATERIAL INDENT. PRE MACHINING VMC/WIRECUT/MILLING ASSEMBLY TOOL TRAIL
Planned completion
Actual start
>
Actual end
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Sep-13
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Primary Indicators
100%
100%
80%
80%
60%
60% 12 40%
APQP Readiness APQP Readiness
12
12
12
12
40%
APQP Readiness APQP Readiness APQP Readiness
GSQM 220
GSQM 220
GSQM 220
20%
0-Jan-00
0-Jan-00
0-Jan-00
0-Jan-00
0%
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
Testing
0-Jan-00
0-Jan-00
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
0-Jan-00
0%
GSQM 220
GSQM 220
Capability
Capability
Capability
Capability
Capability
20%
LRA
LRA
LRA
LRA
LRA
Primary Indicator: Goal Production Preparation Influencing Factors Number of 'Progress Report' elements with Green status 1. APQP Readiness Total number of elements from'Progress Report' Total number of instructions completed MANUFACTURABILITY 2. Process Instructions Total number of instructions needed. Results from Run at Rate, line 25 3. First Time Capability Ideal % of good parts Overall Utilization percentage. 4. Process Efficiency Maximum allowable utilization Number of capable designated characteristics features 5. Process Capability Total number of designated characteristics features 6. Test Achievement 7. Process Implementation % Completed 8. Launch Readiness Audit 9. Sub-Component PPAP Approvals 10. PPAP Package Completion 11. Supplier Ramp Plan DLN Number of tests passed % of total tests High volulme process or Interim Process with Concession Production volumes provided off production intent process Score achieved during event Goal is 100%. Number of sub-components and materials PPAP approved Total number of purchased sub-components/materials Number of PPAP required documents completed Number of PPAP required documents required State of completed supplier ramp plan Ramp planned completed and shipping to releases Enter completed stage of PCM (see comments) Complete Stage 5 by SOP 5 5 5 Target Results
K E Y M E A S U R E A B L E S
PPAP
SUPPLIER SIGN-OFF (MANAGER LEVEL) Function Name (print) Signature Project Leader Purch/Sales Production Control Quality Engineering Design Manufacturing
TRW SIGN-0FF SDE TRW Internal Use only Commodity Mgr/Buyer SQA Name (print) Name (print) Name (print) Signature Signature Signature
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Definition Data is derived from the 'APQP Progress Report'. This metric tracks the percentage of GREEN elements compared to the total number of elements being tracked.
Goal
Results Enter the number of GREEN elements at the time of the report.
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 and inspection instructions needed. Enter total number of process instructions needed for serial production.
Percentage of good parts to the total number of parts produced during the Run at Rate.
Form No.: D_020_4_12
Enter, as a decimal number, the ratio of total parts produced to good parts from the trial run. Enter the number '1,' which represents the production of 100% good, or usable, parts. The Overall Utilization % from the Run at Rate form. Maximum allowable utilized capacity is 100% when the standard shift pattern and CPV are used.
Process Efficiency
Process Capability
The number of designated characteristics with a Ppk > 1.67. Enter the total number of designated characteristics on the drawing.
Enter the number of characteristics, with a Ppk > 1.67, at the time of the review.
Test Achievement
Total number of performance and materials tests that need to be conducted to meet the specifications shown on the 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.
This is the total number of samples that passed all of the required testing at the time of the review.
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Metric
Definition
Goal
Results Enter the appropriate stage of process implementation in regard to manufacturing for serial production. 1. Prototype process is implemented; No released deviation of concession; No containment plan. 2. Intermim process implemented, with partial production intent process; No released deviation or concession; No containment plan. 3. Prototype or partially implemented process; Released deviation or 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
APQP Readiness is derived from the Progress Process Implementation - Data This metric assesses the'APQP level of Report'. This metric tracks the % Completed implementation of the full production percentage of GREEN elements intent process. Processes that are not compared to the total number of fully implemented at the Start-ofelements being tracked. Production require a deviation, or concession, to allow shipment. This document needs to clearly define the state of the process implementation, provide a time line for completing the implementation, list any non-conformities to the drawing and/or specifications, and a containment plan to keep those nonconformances from reaching TRW.
5. Fully implemented process; No deviation or concession required. Launch Readiness Audit A comprehesive audit tool's score, which assesses a process's state of preparation to meet serial production requirements. Form No.: D_020_4_09 The minimum goal for full release for production is 90%. Goal is 100% and entered as "1". The number of approved sub-component and material PPAPs at the time of the report. The score achieved on the Launch Readiness Audit. Enter data as a decimal number.
Number PPAPs approved for the purchased sub-components and materials that makes up the final shipped component/material, and that do not have The number of approved sub-component any deviations, waivers, and/or and materials making up the shipped concessions granted by any tier below component/material. TRW. Number of PPAP submission package elements completed compared to required number. The total number of required elements, or documents, required to be submitted.
The number of elements (or documents) completed for the PPAP package at the time of the review.
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Definition Data element is derived from thea 'APQP Progress This evaluates supplier's ability Report'. This metric tracks to meet ramp-up timing andthe volumes. percentage of GREEN elements compared to the total number of elements being tracked.
Goal
Results Enter the number corresponding to the completed stage from the list below. 1. Has not received any production releases from using plant(s). 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 completion of the safe launch plan, on the PCM (D_020_4_20). Enter number of completed stage at time of review. 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.
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Blanchette / Global Director, SDE
7 D 24-Jun-2013
PROGRAM MILESTONES Event Design Freeze First Off-Tool First Off-Process PV Build PPAP submission Start of Production Date Committed Event Date Committed
Needed
Completed
Needed
Completed
PHASE/ELEMENT STATUS OVERVIEW APQP Phase 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5.1 5.2 5.3 5.4 5.5 Date 20 Element Design FMEA Preliminary Capacity Study Manufacturing Feasibility reviewed Component Design Review Key Supplier Metrics initiated Supplier Project timing plan Open Issues Action Plan created Subcontractor PPAP approval Product Characteristic Matrix Process flow chart PFMEA Control Plan Key Supplier Metrics reviewed Measurement/ Testing equipment Tooling Capital equipment Training Process instructions Packaging Launch Readiness Audit Key Supplier Metrics reviewed ELV/IMDS Safe Launch Plan finalized Supplier Ramp Plan Plant Readiness Review Launch Readiness Audit Appearance Approval Process Key Supplier Metrics reviewed PPAP Launch Readiness Audit Run at Rate Key Supplier Metrics reviewed OK to Launch Sign-Off Needed Committed Complete Percent 100 40 60 80 Status
Progress Report
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
NA
CLICK HERE
Applicable
CLICK HERE
PPAP CHECKLIST
Applicable
CLICK HERE
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Blanchette / Global Director, SDE
B5095904
Tier II
Date:
Customer receiving Operation
Revision:
OEM Customer Tier
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Kojak Heat Treat Benton Harbor, MI Harden & Draw Fine Fasteners, Inc. Benton Harbor, MI M8x20 Weld Stud 59039813A Cold Forming
CUSTOMER
AAA Heat Treat Frederick, MD Harden & Draw ABC Nut Co. Summit, NJ M8x15 Staking Nut 59039812C Cold Forming
Precision Forming Amarrillo, TX Airbag Reaction Can 49019804A Stamping body, end caps, brackets
Process Owner: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
D_020_4_20-PCM
Safe Launch Plan duration is for 90 days after start of production unless otherwise specified. SLP data must be sent to TRW (check one):
Other:
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
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
D_020_4_20-PCM
Date:
Quantity Inspected Quantity Rejected Ppk
Date:
Quantity Inspected Quantity Rejected Ppk
Date:
Quantity Inspected Quantity Rejected
D_020_4_20-SLP
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
D_020_4_20-SLP
Ppk
D_020_4_20-SLP
D_020_4_20-SLP
0.8
0.7
1 Incident
0.6 Incident
0.5
0.4
0
0.2
0 0
Incidents PPM
0.1
0 0
Total 0 0 #DIV/0!
Fault No. Failure Mode Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Action
WEEK Incidents QTY PPM Timing #DIV/0! W14 #DIV/0! W15 #DIV/0! W16 #VALUE! W17 #VALUE! W18 #DIV/0! W19 #DIV/0! W20 #DIV/0! W21 #DIV/0! W22 #DIV/0! W23 #DIV/0! W24 #DIV/0! W25 #DIV/0! W26 #DIV/0! W27 #DIV/0! W28 #DIV/0! W29
D_020_4_20-SLP - QOS
D_020_4_20-PCM Sub-Supplier
Safe Launch Plan duration is for 90 days after start of production unless otherwise specified. SLP data must be sent to TRW (check one):
Other:
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
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
D_020_4_20-PCM Sub-Supplier
100% IN CELL KEY FEATURES VERIFICATION AND CUSTOMER TOUCH POINTS FEATURES TO BE QUALIFIED
Part Description
1 2 3 4 5 6 7 8 9 10 COMMENTS :
The Items Qualified Are To Be Marked With "YELLOW" Paint.
Part Number
Supervisor Signature :
Date :
In Cell Check
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Fail
OPERATION
1 2 3
FEATURES TO BE QUALIFIED
Part Description
Brake Assy RH
Brake Assy LH
1 2 3 4 5 6
* * * * *
* * * * *
Lining identification code Mass weight and rivet presence Date code on shoe PKB rivet crimped washer Pkb lever hook Wheel cylinder screw torque
* *
Part Number
Supervisor Signature :
In Cell (Example)
Date :
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Fail
Quantity Inspected:____________Date:______________
Verification Method
Pass
Item Number
Source of Issue
Distribution:
Open Issues
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Part Number
Contact Information
Supplier
Contacts
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE