apqp with flow of process

Doc.No. : PR/ENGG/01

Rev.No. : 02

Rev. dt : 04.07.2008

Page No.: 1 of 8

PURPOSE1 ) 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

SCOPEApplicable to new process development

Applicable to significant process change & significant design modification

(If new tooling required or supplied by customer)

DEFINITIONS

The Cross 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 Representative ( when required by Customer ) will be invited for CFT meeting

as and when necessary

The person to liaise with Customer and to represent Customer in internal functions will also be identified .

CFT Leader can co-ordinate with any other 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


Rev.No. : 02

Rev. dt : 04.07.2008

Page No.: 2 of 8

Primary Secondary Process Owner : Engineering

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Mkt PROCESS CHART Related Document

Receive New Product Enquiry with Enquiry register

Drawing and or sample.

Quotation

No

Yes

Formation of CFT Team for project CFT form

Yes

Process flow



Assign Request for Quotation No. to each Drawing and Update RFQ Tracking Sheet.

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

Start

Business decision toprocess enquiry

Customer / productinformation &

standards given for product adequate ?

Regret offer

Clarify with customer

A

NO


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Page No.: 3 of 8


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Send to Approval Costing sheet

Approval

No

Yes

P.O.

APQP Review Meeting ( Gate 1) Review Record

Part Drawing

Check list



Prepare " Product Costing Sheet", Tooling Costing Sheet.

Quote to Customer along with Standard Terms Conditions

Negotiate & Resolve with Customer.

P.O/Tooling Order from Customer

1) Notify customer for

any slippage in PSW Timing

plan 2) Initiate recovery action to

improve Red point

Prepare APQP Timing Plan & ensure for adherence.

Receive new drawings & Quality documents from customer

List of customer drawing

Review and check customer data as per check list(AAL/D/CH/01)

Review of DFMEA , Product history, Quality rating, Drawing Dimns.

Clarifications..

Review for Clarification required from customer if any

Discuss with customer & get clarification , resolve issue if any.

A

Acceptable

B

Identify & development of sub supplier

NO YES

Need of sub -supplier

H

Start APQP activity of sub supplier as per doc.no AAL/CFT/F/07 . ( Sub supplier APQP Gate Ways )


Rev.No. : 02

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Prepare Amtek Drawing Amtek Drawing

Issue Register



Get approval from customer & maintain as a Master copy

Master copy drawing file

Track Five Gateway timing plan & Update GYR Status

Put controlled copy stamp & issue to concern dept.

Prepare Simulation data for analysis

CAD data for tooling preparation

Make changes

OK

Release Tooling Design to concern dept with necessary controls

OK

Not Ok

B

C

Pass all drawing specification,significant,characteristics(CC,SC,PTC,HIC details to supplier for child part development

Sample submit to Amtek

OKREJ

PPAP from sub- supplier as per level 3 requirement.

K

H

Convey rejected points to sub supplier & take corrective action if any.


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Review New Equipment, Tooling & Facilities

Identify Special Characteristic Special char. sheet

APQP Review Meeting ( Gate 2)

No

Yes

Customer approval

Prepare Process parameters sheet Process Para. sheet

Review Process Flow Chart Flow chart



Develop Prototype Control Plan & Proto samples.

Validation of samples for appearance & dimensional aspects ( reliability requirement,

if any) & submit to customer.

C

Any Prototyperequirements ?

D

1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point

Use PPAP approved part from sub- supplier

K


Rev.No. : 02

Rev. dt : 04.07.2008Page No.: 6 of 8


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Prepare floor plan Floor plan

Review PFMEA

Develop Pre-launch / production Control Plan Control plan

Develop process Quality instructions /Work instruction

Operator instructions

Review Record

Make corrections if any.

Inspection by QA




Sampling Trial for casting & machining ( if involved. )




improve Red pointValidation of samples (product & process) ,

confirm parts are meeting dimensional , functional (& reliability requirement, with sub

supplier part if any) .

E

D


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Lay out Inspection by QA

No

Yes

Develop SPC study Plan Spc study plan

No

Yes

Develop MSA study Plan MSA Plan

Dimensional Verification

Validation record




Sample Submission to customer ( With sub supplier part if any )

1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red

E

Any SPCrequirements

Are New MSAstudies required

Any ProductionTrial requirements

of Customers

F


Rev.No. : 02Rev. dt : 04.07.2008

Page No.: 8 of 8


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Customer feedback

Corrections if any.

PPAP File

Product quality planning summary & sign-off Sign off sheet

APQP Review Meeting ( Gate 5) Review sheet

Track 5000 components or 3 months

Prod. Record supplies (whichever is earlier ) for any Concern

No

Yes

Control plan

ECN



PPAP Submission with all applicable documents. (Default level 3 & min. 300 parts unless specified.)




improve Red point

Develop, Track Action Plan & review FMEA for high RPN.

Any improvement or modification in process after PPAP approval must inform to internal

Quality for approval

F

Any concerns

Stop

apqp with flow of process

Documents