2007 APQP Program MGMT Classroom

Supplier APQP Overview
TRWs Electrically Powered Steering and Electronic

Stability Control System work together to help keep
vehicles on the road. And these lives safe.
2005 TRW Automotive
TRWs High Performance Brake Caliper.

And the life it helps protect.
2005 T RW Automotive
The Global Leader in

Automotive Safety Systems
TRWs Airbag Electronic Control Unit.

And the life it helps protect.
2005 TRW Automotive
2005 TRW Automotive
TRWs Side Impact Rollover Protection System.

And the lives it helps protect.

What is the goal of this module? What do we want to
achieve?
To provide an understanding of what the Supplier
Development Teams responsibilities are, in terms
of the APQP process.
To provide an understanding of the roles and
responsibilities between the cross function
departments (engineering, purchasing, program
management, operations).
To provide an understanding of the importance of all
cross functions working together to achieve a
flawless launch.
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Business Policy Manual (BPM)
What is the BPM?
Supports goal of one

company, one process,
one standard.
Repository for both
automotive and product
line processes.
D: Supply Management
contains supplier APQP
documents.
Click on the picture to find out.
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Business Policy Manual (BPM)

Where can I find the BPM?
A link can be found
on the TRW
Automotive
homepage or any
other product line
website.
Or you can type the URL into your browser

address window:
http://oeforums.shrluk.trw.com/bem/dispatch
.exe/bpm_docs
44
Click picture for links

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GDPIM
What is GDPIM?
Click
Here
Is it the Global Design

Process for Integration &
Management?
or
Click
Here
Click picture to
start
55
Is it the Global Development

& Product Introduction
Management?
Congratulations!
No, Try Again
That is correct.
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GDPIM
Cross
Functional
Team
CLICK HERE
Defined
CLICK
HERE
Phased
CLICK
HERE
Tools
&
Approach
Techniques
GDPIM
Checklists, phase
definitions,
priority
assessments.
Used for
customer
specific product
launches.
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Consists of Program
Manager, Engineering,
Operations, Quality
and Purchasing.
Application
CLICK HERE
Engrg
Module
Core
Engrg
CLICK
HERE
Module
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Pre-defined
stages with exit
reviews assure
containment of
issues.
Applies to development
of new products.
GDPIM
Where can I find the GDPIM procedure and related
documents?
GDPIM is found in
the Business
Policy Manual,
Section A.
Click on the compass to
find out.
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GSQM
What is the GSQM?
The GSQM is TRWs Global Supplier

Quality Manual.
This manual documents TRWs

expectations and requirements from
its direct material supply base.
The scope of the manual includes all

suppliers who directly affect the
quality of production materials.
It does not include:

MRO
Internal suppliers
Click on picture for answer
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GSQM
The GSQM is divided into 3 sections:
Supplier Qualification
Requirements
Automotive
Requirements
Definition of the
application of the
document.
Links to all
referenced forms
and procedures.
Governmental and
Environmental
regulation
compliance. Introduction
Documents
Table
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Serial Production
requirements
Continuous Improvement
Responsibilities and
formats.
99
APQP and PPAP

processes
GSQM
Where is the GSQM Located:
Internally it can be found at

http://vinet.livmi.trw.com/ on
the Intranet, or
It can also be found at TRW

Automotive
(http://www.TRWAuto.com)
Click on picture for locations
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What is APQP?
Is it???
Alternative Product Qualification Process which is a systematic
approach, which results in a components approved PPAP, when the
drawing is released late.
Accidental Production of Quality Parts a supplier philosophical

approach resulting in unplanned conformance to the drawing.
Advanced Product Quality Planning a systematic approach, which

results in plan for controlling a manufacturing process and/or product in
order to meet the customers requirements.
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What is APQP?
OOPS! A good guess,
but not the correct
answer. Click here to
try again.
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What is APQP?
It can also be used
for drawing
changes, supplier
process changes
and tool moves.
Finishes with
full approval,
or release of
PPAP.
Starts in Design
Validation phase
of GDPIM.
Click
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1 on each sign if more information
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4 Key Elements of APQP

Special
Characteristics
A method of identifying those component

features that affect fit, form, function,
assembly and manufacturability.
Manufacturing
Feasibility
The ability to manufacture the component,

in sufficient quantities and with acceptable
quality, to the customers requirements.
Control plan
Failure modes
effects
analysis
Click on term to see definition.
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The listing of controls used, based on

the FMEA, detailing characteristics,
methods, frequencies, and reaction to
process non-conformances.
A study of what can go wrong in a
manufacturing process and what controls
will be use to reduce the risks.
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Now that you are prepared, lets start our overview
What is the primary form of communication in and out of TRW?
(click on what you think is the correct answer)
AL
S
PO
O
PR
The drawing is correct. It represents

WRONG.
AGAIN!
the focal point
for all TRY
reviews,
activities
and actions.
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Lets take you through a scenario as an example
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APQP Scenario
If you were taking your family
on vacation, driving from it is
doubtful that you would leave
your house spontaneously,
without any planning.
First, you would decide on
how long you would need to
make the trip.
You need so much time to
travel to and from your
destination.
And, of course, you would
want to spend enough
time once there.
Click on car
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APQP Scenario
Next, you would need a map and
determine which route you would
be taking.
Is there enough time to take the
scenic route or are you just driving
to get to the destination as fast as
possible?
How long will the kids be able to sit
in the car?
What about meals?
Hotels?
Road Construction?
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APQP Scenario
If driving, you will need to
get the car ready for the trip.
Are new tires needed?
When did you last get an
oil change?
Tune-up?
Dont forget the house!
Stop the mail delivery .
The newspaper.
119
Click on picture
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APQP Scenario
How does this relate to a TRW launch?

(click on arrow for relationship)
Length of Vacation
220
Launch Window
Road map
Product drawing
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APQP Scenario
(Click on arrows)
Special (designated)
Characteristics
Places we must see
221
Travel itinerary
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Process Flow
Diagram
APQP Scenario
(click on arrows)
This
and
Not this,
222
Design FMEA
not this
but this
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Process FMEA
APQP Scenario
(click on arrow)
Packing, shopping,
things to do lists,
agendas,
itineraries, etc.
223
Control Plan
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Supplier Component APQP Process

The process begins after
TRW has been awarded the contract from

our customer.
The part has been quoted.
The production supplier has been identified.
For components requiring a long lead time for
tooling and/or capital equipment, a purchase
order to cover the tooling has already, or will
soon be, issued.
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THE KEY PLAYERS ARE:
Responsible
for supplier
selection &
commercial
relationship.
Responsible for
product design
and functionality.
May include
both Core and
Applications.
Supplier
Commodity
Manager
Engineer
Leads the
team;
responsible
for quality of
launch.
Program
Manager
Responsible for
manufacturing
the component to
meet the
drawings
requirements.
Launch
Coordinator,
Logistics and
Manufacturing
Engineering
participate.
Operations
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(Click
picture for explanation)
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Supplier
Development
Engineer
Works with
supplier to
validate
components
manufacturing
process.

The first step is the Component Priority Assessment (CPA)
(click on picture)
Who Attends?
What is it?
A process to identify which
component(s) and/or
supplier(s), involved in any
given launch, require a focused
effort from Kick-off to
Production by the SDE and/or a
226
cross-functional
team.
Lead by: NPI

Supported by:
Program Management
Engineering
Commodity Management
SDE/SQA
Operations
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Component Priority Assessment (CPA) (click on picture)
BENEFITS
Identifies early in a program which components,
especially in complex assemblies, are likely to
create issues.
Focuses limited resources, i.e., SDE, on the critical
few suppliers, resulting in a higher quality APQP
process.
Defines which processes, in the SDE toolbox, which
are employed based on element scores.
Brings organizational cross-functional effort to
identify and resolve issues as they arise.
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Two sections; one for Early Sourcing and the other for
production.
Scoring is different for Early Sourcing.
Total scores are automatically calculated, with status or
2 category shown.
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EARLY SOURCING ASSESSMENT

Eight categories.
Focus is on supplier, schedule and component complexity.
Can be used for core or application projects.
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LAUNCH
Scoring, based on defined criteria, may be 50, 10 or 1.
Overlap of two categories.
Each part categorized as A, B or C, which defines SDEs
3degree of involvement.
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Component Priority Assessment (CPA) (click here)

THE PROCESS:
1. Select First
Part Number
x
2.
4. Select Next
Part Number
3.
331
3. Form Automatically
Calculates Total Score
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2. Evaluate
Against Each
Risk
Category

CATEGORY A COMPONENTS:
Highest chance of launch issues.
Requires total score of 200 or more.
Should be few in number; about 35%. These are the critical few.
Best represents new technologies,
processes and/or suppliers.
Requires assignment of a Supplier
Champion based on assessment
category scoring.
Does not include chronic issue
3 suppliers.
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CATEGORY B COMPONENTS:
Moderate chance of launch
issues.
Total score is from 100 to 199.
Should be few in number about
10-15%.
Best represents chronic issues,
technology evolution and/or poor
quality performance.
Utilizes selected tools based on
scoring.
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CATEGORY C COMPONENTS
Low chance of launch issues.
Total score of less than 100.
Should be the majority of the
components.
Best represents current
technologies, processes and
acceptable quality performance.
APQP conducted by supplier;
PPAP only submission
requirement.
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Component Priority Assessment (CPA).
DOCUMENTATION:
Work Instruction:
D_020_3_03
(click on picture)
335
Form
D_020_4_08
Assessment
Element Definitions
Utilization Matrices
Location
Business Policy Manual
Section D
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5 PHASES
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Supplier Component APQP Process: 5 Phases

PHASE 1: Supplier Kick-off and Planning
Goals (click on picture to left)
Communicate program/component
functionality.
Establish project time line, goals and
expectations.
Identify issues with the suppliers
ability to manufacture the component.
Scope (click on picture at right)
Applies to all Category A components.

Applies to Category B and C components
based on the SDEs choice.
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PHASE 1: Supplier Kick-off and Planning
Begins with award of new business
Ends with completion of the Kick-0ff

Meeting/Supplier Component Design
Review.
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PHASE 1: Supplier Kick-off and Planning INPUTS
DELIVERABLE
RESPONSIBILITY
Engineer
Engineer
Starts long lead tooling early enough to

meet program timing; Process design is
more robust.
Identifies critical features and
functionalities that can be incorporated into
process and tooling design.
Program Mgr
Communicates program needs and

deliverables to all participants.
SDE
Defines expectations and

validation requirements.
Buyer
339
IMPACT
Establishes capacity requirements

the suppliers process must meet.
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PHASE 1: Supplier Kick-off and Planning INPUTS
DELIVERABLE
440
RESPONSIBILITY
IMPACT
Supplier
Allows correlation of component and

program time lines and identification of
potential conflicts.
Supplier
Documents suppliers estimated ability to

meet program volumes.
Supplier
Documents suppliers ability to meet the

drawings requirements.
Supplier
Allows for early correction of

manufacturing approach when necessary .
Generates dialogue, and coordination

between supplier and using facility in
Supplier
regard
to how the part is measured.
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PHASE 1: Supplier Kick-off and Planning OUTPUTS
DELIVERABLE
441
RESPONSIBILITY
IMPACT
SDE
Documents review of drawing, technical

and commercial issues.
Supplier
Displays suppliers plan for meeting

program deliverables.
Supplier
Identifies all suppliers, regardless of subtier level, who impact the final part.
Supplier
Defines all special characteristics and

point in process they are manufactured.
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PHASE 1: Supplier Kick-off and Planning OUTPUTS
DELIVERABLE
442
RESPONSIBILITY
IMPACT
Supplier
Single document used to capture key

deliverables, their target completion dates,
and progress made.
Supplier
Captures all open issues in single

document, along with resolutions,
responsibilities and target dates.
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PHASE 1: Supplier Development Tools-APQP Workbook
In the Business Policy Manual and

the GSQM.
D_020_4_003.xls
A collection of APQP forms that

would be used regardless of
priority ranking.
443
APQP Progress Report, Supply

Chain Map, Key Metrics Report,
Product Characteristics Matrix and
Open Issues Action Plan.
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PHASE 1: Supplier Development Tools-APQP Progress Report
Provides supplier timing and
progress on key APQP deliverables.
Periodic submission to SDE for all
priority A and B components.
Further detail, i.e., tool build timing,
captured in supplier timeline.
Status of completion one of the Key
Metrics.
444
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PHASE 1: Supplier Development Tools Supply Chain Map
Used to define deep and/or complex supply chains.

Identifies suppliers that affects quality of special characteristics.
4 Further defined in Product Characteristics Matrix (PCM).
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PHASE 1: Supplier Development Tools Key Metrics Report
Focuses APQP on results
rather than events.
Twelve key metrics allow
multiple updates to
demonstrate current status and
progress over time.
Four primary indicators provide
a quick picture of the process.
Automatically generates a
graph.
Operational definitions
provided.
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PHASE 1: Supplier Development Tools PCM
Ties DFMEA,
Component PFMEA,
Control Plan and Supply
Chain Map together.
Forms basis of Safe
Launch Plan (SLP) and
is hand-off from SDE to
Operations/SQA.
Engineering
participation essential to
success.
447
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Initiated at Design
Review.

PHASE 1: Supplier Development Tools Open Issues Action Plan
Combines all separated

action plans into a single
document.
Started at Kick-off
meeting.
Supplier is owner of the
document.
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PHASE 1: Supplier Development Tools Design Review
Found in Business Policy

Manual and GSQM.
Document No: D_020_4_04
Cross functional participation
critical for event success.
Includes detailed review of every
dimension, note and
specification on.
Unresolved issues identified at
the Design Review often create
launch and serial production
issues.
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PHASE 1: Supplier Development Tools Launch Readiness Audit
Found in Business Policy Manual

and GSQM.
Scored audit grades suppliers
state of preparation for start-ofproduction.
Is one of the Key Metrics.
Requires a score of 90%, or more,
to show readiness for launch.
Can be used at different points
throughout APQP to measure
progress.
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PHASE 2: Equipment and Tool Design

Resolve issues identified in APQP 1.
Approve the suppliers design for
tooling, process and/or gauging.

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PHASE 2: Equipment and Tool Design
Begins with completion of Kick-off

meeting and/or Design Review
Ends with the suppliers completion of

their tooling, equipment and/or gauging
design.
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PHASE 2: Equipment and Tool Design INPUTS
DELIVERABLE
553
RESPONSIBILITY
IMPACT
Engineer
This defines the process development

needed. Lack of special features and
correct specifications will carry over into
production.
Engineer
Identifies critical features and

functionalities that can be incorporated into
process and tooling design.
Buyer
Updated volumes assure tools ability to

meet product requirements.
Supplier
Communicates issues identified during

the component design review and
captures new issues as they arise.
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PHASE 2: Equipment and Tool Design INPUTS
DELIVERABLE
554
RESPONSIBILITY
IMPACT
Supplier
Updated milestones for process

development.
Supplier
Defines all special characteristics that

need consideration in the tooling design.
SDE
Open manufacturability issues identified in

previous phase need resolution to properly
complete tooling design.
Supplier
Preliminary concepts refined based on

results of design review.
Supplier
Preliminary concepts refined based on

results of design review.
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PHASE 2: Equipment and Tool Design OUTPUTS
DELIVERABLE
555
RESPONSIBILITY
IMPACT
Engineer
Updated to reflect resolution of suppliers

manufacturability issues, latest
information, improved design.
Supplier
Updated to include process build details

and milestones. Process realization
progress can be measured from this.
Supplier
Final designs released to suppliers

vendors for build and/or procurement of
necessary manufacturing process
elements.
Supplier
Updated to reflect closure of completed

items and addition of new issues that
have been identified.
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PHASE 2: Equipment and Tool Design OUTPUTS
DELIVERABLE
RESPONSIBILITY
Supplier
556
IMPACT
Updated to reflect progress made since

Phase 2.
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PHASE 3: Product/Process Realization

Build tooling, equipment and/or
gauging necessary to manufacture
component.
Resolve issues identified in previous
phases.

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PHASE 3: Product/Process Realization
Begins with completion of designs.
Ends with the suppliers approval, at their

vendors locations, to accept the tooling,
equipment, and/or gauging.
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PHASE 3: Product/Process Realization INPUTS
DELIVERABLE
RESPONSIBILITY
Engineer
Updated drawings resulting from

completed tests and various builds
continue to keep the supplier informed.
Supplier
Final designs released to suppliers

vendors for build and/or procurement of
necessary manufacturing process
elements.
Supplier
559
IMPACT
Continuing definition of controls and, when

applicable, expansion of detail to sub-tier
suppliers.
Updated to reflect closure, or progress,

on open issues and addition of any
Supplier
newly
identified problems.
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PHASE 3: Product/Process Realization INPUTS
DELIVERABLE
RESPONSIBILITY
Supplier
Continues to be updated to reflect

progress and/or timing related changes.
Supplier
Suppliers Process FMEA contributes

process knowledge, lessons learned,
potential mistake proofing opportunities
and other process controls to be used.
Supplier
660
IMPACT
Document that defines all of the suppliers

controls starting with Receiving Inspection
and ending with the shipment to the
customer.
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PHASE 3: Product/Process Realization OUTPUTS
DELIVERABLE
661
RESPONSIBILITY
IMPACT
Engineer

Supplier
Updated to include process build details

and milestones. Process realization
progress can be measured from this.
Supplier

Supplier

Phase 3.
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PHASE 4: Pre-PPAP
Generate first pieces off process.
Identify tooling/equipments
manufacturing capability.
Make necessary process
refinements/adjustments to meet
drawing.

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Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 4: Pre-PPAP
Begins with suppliers receipt of tooling,

equipment and/or gauging at their
manufacturing location.
Ends when the supplier has satisfactorily

completed adjusting the process to
produce acceptable parts.
663
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 4: Pre-PPAP INPUTS
DELIVERABLE
664
RESPONSIBILITY
IMPACT
Engineer

Supplier
The suppliers manufacturing process and

any test/measurement gauges needed.
Supplier
Defines Safe Launch Plan, where required,

and documents process capability
associated with special characteristics.
Supplier
Updated to reflect closure of open

issues and addition of any newly
discovered problems.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 4: Pre-PPAP INPUTS
DELIVERABLE
RESPONSIBILITY
Supplier
Supplier
Supplier
665
IMPACT
The process developed to manufacture the

material/component.
Suppliers Process FMEA contributes

process knowledge, lessons learned and
potential mistake proofing opportunities.

customer.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 4: Pre-PPAP OUTPUTS
DELIVERABLE
666
RESPONSIBILITY
IMPACT
Engineer

Supplier
The suppliers process that

manufactures components for serial
production at TRW.
Supplier

Supplier

Phase 3.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 4: Pre-PPAP OUTPUTS
DELIVERABLE
RESPONSIBILITY
Supplier
Supplier
Supplier
667
IMPACT
Suppliers Process FMEA is updated to

reflect any new failure modes discovered
or modify level of Severity, Occurrence
and/or Detection.
customer.
Twelve QOS (Quality Operating System)

measurables that indicate the status of the
APQP process and readiness for start-ofproduction.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 5: PPAP
Complete PPAP validation run at
supplier.
Review and approve suppliers PPAP
submission package.
Start Safe Launch Plan.

Applies to all components.
668
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004
PHASE 5: PPAP
Begins when the suppliers

manufacturing process is ready to
produce parts.
Ends when the suppliers PPAP

submission package is
approved/released.
669
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 5: PPAP INPUTS
DELIVERABLE
RESPONSIBILITY
Engineer

Supplier
The process realized to manufacture the

component.
SDE
770
IMPACT
AIAG Level 3 submission plus any

additional needed documentation.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 5: PPAP OUTPUTS
DELIVERABLE
Supplier
The suppliers production run that the

PPAP submission will be based on.
Supplier;
SDE
For Category A and B components a

formal Run at Rate is conducted to verify
the suppliers actual capacity.
Supplier;
SDE
Supplier
771
IMPACT
RESPONSIBILITY
A scored audit designed to evaluate the

suppliers state of readiness for launch.
A collection of documents based on the

AIAG PPAP Manual and additional
TRW requirements.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 5: PPAP OUTPUTS
DELIVERABLE
RESPONSIBILITY
Reviewed, and signed off on, by using

plant(s) and SQA, this initiates the Safe
Launch Plan at both the supplier and
TRW.
SQA;
Plant
772
IMPACT
Supplier

have been identified. All issues are to
be closed to complete the PPAP
process.
Supplier

Phase 4. Full PPAP approval/release
closes this document.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 5: Supplier Development Tools Run at Rate
Found in Business Policy Manual and GSQM.

Detailed format incorporates Equipment Allocation to assure sufficient
capacity is in place to meet production requirements.
773
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 5: Supplier Development Tools PPAP Requirements

and GSQM.
Lists PPAP package elements
and their associated form
numbers (where applicable).
Establishes consistent order of
documents within the PPAP
package.
Defines different levels of
submission.
774
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

PHASE 5: Supplier Development Tools PPAP Checklist
and GSQM.
Lists in addition to the PPAP
package elements specific things
to look for associated with those
elements.
Can be used by both TRW
reviewer and supplier.
Intended to drive global
consistency in acceptance
standards for PPAP packages.
775
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

When things go well and we are working together as a team, we
see great results.
5.2 Combustion Plate Case Study

I dont know if this was a success story, but more of
an amazing resurrection of a part that was
smoldering in the ashes
TRW Mesa Core Engineering
776
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004
5.2 Combustion Plate

Case Study
The 5.2 Inflator Combustion Plate story actually took place

after the start-of-production.
This took place in the Summer of 2000. The OSS SDE group
had just gone through merging two different groups, Air Bags
and Seat Belts, and also had a new management team.
Many of the tools existed in pocketed areas and were not

used and/or available at the programs beginning.
The component had significant issues making it virtually

impossible to manufacture. Demanding machining
requirements increased cycle times to the point it was
necessary to add several additional suppliers to meet the
777requirements.
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study
The tools below were used to address the issues and SDE has
taken several of these and incorporated them into the global
Supplier APQP process.
Focused Design Reviews
Intensive Supplier Processing Analysis Including

Equipment and Tool Design and Capacity
Run at Rate and Contingency Plans
Cost of Quality and Yield Analysis
Engineering Collaboration for Design for Manufacturability
778
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004
5.2 Inflator
Primary Propellant
Secondary
Chamber
Propellant Chamber
Combustion Plate
Retention Stud
Location
Initiator
Retainer
Initiator Seal
Nozzle
Initiator
Retention Stud
Igniter Assembly
Seal
Rupture Disk
Enhancer
Propellant
Orifice
Isolation Disk
Diffuser
Diffuser Port
Canister
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
79
01.09.2006
April19.2004
Propellant
Combustion
Plate

Case Study - Overview
Inflator design customized to meet DCX specific module
application.
Design drove the combustion plate geometry and features.
Initial launch did not have necessary criticality required to
ensure manufacturability of the component.
Combustion plate was resourced twice and involved DCX
problem resolution specialist on site at supplier location
(MSI). This was the start of the intensified TRW DFX
intervention.
Inflator costs were driven to 3X the target price by this one
component alone.
880
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Design
881
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Key Elements
Cycle Time Issues Quoted vs. Actual

Forged, Stamped and Machined Supply Chain
Excessive Burrs
100% Gauging
Perishable Tooling and Excessive Tool Wear
Machining Methods (Chucking and Positioning with Datums)
Equipment Robustness
Supplier Transition and Knowledge Transfer
882
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Process/Cycle Time Optimization
Insufficient capacity drove a detailed data collection to understand where
the bottlenecks were.
883
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Resolution Activity - Tooling Optimization
Tool organization
and wear study
initiated as this
translated into
costs and
machine
downtime.
884
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Process/Cycle Time Optimization
Actions were defined based on the studys results.
Description of Change
Benefit
Status/Action
Eliminate Ponds
Decreases facing and turning time amounting to a 4

sec. savings.
An insert (magic) drill can be used increasing tool life
and decreasing cycle by 4 sec.
A complete operation, chamfering can be eliminated
resulting in a 12 sec. reduction.
Engineering change in
progress. Next heat of forges
to have pond omission (8/27).
Increase tolerance of either

diameter or true position for 6mm Cbore
Number of tool feed advances will be reduced by 2/3rd

and 9 sec.
TRW engineering to review

and respond by 8/25
Change -16 chamfer

tool to spot drill
Tool change should result in a 5 sec. advantage
MSI to order tool and test by

8/30.
Increase RPM on bottom endmill
Speed change should realize 3 sec. savings
MSI technician to change and reevaluate time on 8/23.
Bypass autoload operation
Autoload operation potentially less efficient than

operator positioning-estimated savings of 5 sec.
MSI to perform trial run on

fifth Wasino and evaluate
once machine is running.
885
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Resolution Activity: Supply Chain
Variation introduced into the process by stamping a net forged part.
Ultimately this translated into difficulty in maintaining true position for the
igniter ports. A new datum (pts.) would need to be added.
Stamped
Features
Added additional
operation to
machine flats to
create fixturing
location to
ensure true
position
Machined
Features
886
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Resolution Activity: Gauging
100% Gauging was required on the buttress threads (angular tolerance
for initiator orientation) because of the large amount of yield loss.
Gauging was performed with threaded inserts shown below which
quickly worn down the threads after gauging several hundred per day.
Only one set was manufactured and no discussion was included in the
design review. Issue identified and LT reduced to ensure adequate
amount of inserts.
887
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Resolution Activity: Excessive Burrs
Ponds (designed for weight reduction) were eliminated.
Special deburring tools were developed to allow operators to reach the
burr locations and remove burrs.
Thermal deburring methods were explored.
Mechanical deburring and relief angles for tooling were explored.
888
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004
Burr Locations

Case Study - Resolution Activity: Cycle Time Analysis
Extensive analysis with equipment provider to identify gaps in
quoted versus actual cycle time to perform specific
operations. This required downloading of CNC code (cannot
see operation in closed chamber).
Analysis shows that only 3 out of 5 operations where
expected to meet schedule this was partly due to various
second sources and the inability to clearly communicate
schedule requirements.
Analysis clearly shows the improvement required in terms of
additional equipment and the use of improved fixtures to
eliminate need for re-chucking.
889
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Current
The bottleneck
operation produces
less than the need
volume
990
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Current
991
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

Case Study - Resolution Activity: Costs
A cost model was developed to ensure 3rd manufacturing source would
include accuracy in the cost structure of the component and offer a
competitive price. (MSI was asking for $15-16, Hastech price was $7).
992
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

What do we need to fix
Supplier APQP follows the pareto principle. That is 20% of the

components require 80% of the effort.
Full, cross-functional participation is required at the following events:

Component Priority Assessment
Supplier Kick-off Meeting
Component Design Review
Launch Readiness Audits
Manufacturable designs, with clearly defined special characteristics,

sufficiently early in the program to assure suppliers can build and tunein their processes to meet drawing expectations and requirements.
Ownership of the suppliers by the launch team.
Escalation of show stopper issues to upper management within the

product lines.
993
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004
APQP Summary
Successful component APQP is a cross-functional effort.
TRW Supplier Development has a well-defined toolbox that if given
sufficient resources and support can address and resolve significant
issues before start of production.
For the 20% of the components that may critically affect any launch,
lack of sufficient information or issue resolution early in the process
will cause issues during launch and serial production.
994
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004
QUESTIONS?
?
995
TRW
Automotive
2006
TRW
Automotive
Inc.Inc.
2004
01.09.2006
April19.2004

2007 APQP Program MGMT Classroom

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Supplier APQP Overview

TRWs Electrically Powered Steering and Electronic

2005 TRW Automotive

TRWs High Performance Brake Caliper.

The Global Leader in

TRWs Airbag Electronic Control Unit.

2005 TRW Automotive

2005 TRW Automotive

TRWs Side Impact Rollover Protection System.

Supplier APQP Overview

Business Policy Manual (BPM)

What is the BPM?

Supports goal of one

Click on the picture to find out.

Business Policy Manual (BPM)

Or you can type the URL into your browser

Click picture for links

Is it the Global Design

Is it the Global Development

The GSQM is TRWs Global Supplier

This manual documents TRWs

The scope of the manual includes all

It does not include:

Click on picture for answer

APQP and PPAP

Internally it can be found at

It can also be found at TRW

Accidental Production of Quality Parts a supplier philosophical

Advanced Product Quality Planning a systematic approach, which

4 Key Elements of APQP

A method of identifying those component

The ability to manufacture the component,

The listing of controls used, based on

Supplier APQP Overview

The drawing is correct. It represents

Supplier APQP Overview

118Click on picture to proceed

How does this relate to a TRW launch?

Places we must see

Supplier Component APQP Process

TRW has been awarded the contract from

Supplier Component APQP Process

Supplier Component APQP Process

Lead by: NPI

Supplier Component APQP Process

Supplier Component APQP Process

Component Priority Assessment (CPA) (click on picture)

Supplier Component APQP Process

Component Priority Assessment (CPA) (click on picture)

EARLY SOURCING ASSESSMENT

Supplier Component APQP Process

Component Priority Assessment (CPA) (click on picture)

Supplier Component APQP Process

Component Priority Assessment (CPA) (click here)

Supplier Component APQP Process

Component Priority Assessment (CPA) (click on picture)

Supplier Component APQP Process

Supplier Component APQP Process

Supplier Component APQP Process

Component Priority Assessment (CPA).

Supplier Component APQP Process

Supplier Component APQP Process: 5 Phases

Applies to all Category A components.