Download - APQP Workbook
-
7/23/2019 APQP Workbook
1/20
Supplier APQP: Four Phases
APQP -> Phase 1 APQP -> Phase 2 APQP -> Phase 3
Supplier Kick-Off and Planning Product/Process Realization Pre-PPAP
Identify MEI and Supplier team
contacts/roles/responsibilities
Create and/or review DFMEA as appropriate
depending upon design resp.Pre-production run
Communicate and initiate Key Supplier Metrics Develop process flow chart (diagram). Process capability study
Initial Supplier Program plan and timingCreate & review preliminary process flow
diagram, PFMEA, and Control Plan.Finalize PCM: prepare for Safe Launch
Conduct Cross-functional component design
review (doc is located in GSQM)
Finalize PCM & use document for any pre-
product part runs.Finalize PFMEA and Control Plan
Create preliminary Product Characteristics Matrix
(PCM) - Safe Launch PlanConfirm tooling and gage construction progress. Review Supplier Ramp Plan
APQP Requirements Develop Process Instructions Launch Readiness Audit: document key met
Equipment Tooling & gage concept/design
review.Finalize Process capability study Plan
Re-qualify equipment, tooling & gaging as it
moves between supplier site(s)
Review MEI PPAP Requirments with the supplier
(per MEI PPAP Checklist)
Validation review of "1st Off" tool/part
condition(s). Address any issues that can't becontained w/n program timing. Appearance Approval (as appropriate)
Review supplier's manufacturing feasibility
document(s)Floor plan layout Supplier participates in Plant Readiness Rev
Review preliminary capacity study & initial
supplier master schedule plan
Update previous phase open issues and key
documentsReview status of Key Supplier Metrics
Iniate Open Issues DocumentUpdate previous phase open issues and key
documents.
A= MEI SDE will coduct APQP 1 - 4 w/ Supplier
B= MEI SDE will conduct APQP 1 and 4 w/ Supp
C=
PPAP only to SDE. Supplier is still responsib
maintaining APQP 1-4.
Component Criticality Rating
Magna Electronics (MEI) - 4 Phases of APQP for Supplier Develo
Date: 14 May, 2008
Rev. A Magna Electronics APQP Woorkbook
-
7/23/2019 APQP Workbook
2/20
Product
Characteristics Matrix -
Tier II
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 MEI'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.
Product
Characteristics Matrix -
Sub-Supplier
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.
Open Issues 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.
Contacts Lists the individuals involved in the component(s) launch, for both MEI and the supplier, and their respective contact
information. This tab is optional and may be used as needed.
Key Metrics Definitions Operational definitions for the twelve key metrics. Explains the metric and its method of calculation.
MEI PPAP Checklist &Document ".ZIP"
Folder
It is an expectation of MEI that the PPAP Checklist is used for each new part submission to make sure that all requiredPPAP elements are submitted free of the errors that have been historical observed. MEI is confident that if the PPAP
Checklist is used that it will help insure expedited PPAP approval. Please use the embedded PPAP ".ZIP folder" to
make sure that all required PPAP elements are submitted in a softcopy format that helps with ease of review and
document storage.
Format to be used for a weekly summary of the inspection results from the Safe Launch Plan. This information will be
used as part of the decision making process for the removal of the Safe Launch Controls.
PCM - Weekly QOS
Report
Supplier APQP: Table of Contents
Blank Time Line Suppliers are required to create a Master Time Line for the launch of the awarded component(s). It is expected that a
Gantt chart is used as the format. For those suppliers who do not have software available to meet this requirement, a
blank time line is provided for their use.
Shows the 4 APQP Phases and the activities that occur within them.Cover
Table of Contents Lists all of the forms and examples included in this workbook. The Worksheet with "Tabs" highlighted in YELLOW require
supplier documentation and reporting back to MEI SDE.
Supplier FeasibilityStatement
In accordance with The Automotive Industry Action Group (AIAG) and OE specific requirements, the supplier's teamfeasibility commitment document initiates the MEI APQP process. Unless exceptions or concerns are communicated to
MEI as part of the quoting process it is the assumption that the supplier will be providing product that is fully compliant to
all applicable drawings and specifications.
Supply Chain Map Form for showing multi-tier supply chain relationships involved in providing the component/assembly to MEI. The
information documented here will also be used in the creation of the Product Characteristics Matrix (PCM).
Key Metrics Report Key Metrics contain those elements that contribute to a successful launch. This form allows for four reviews. The
minimum requirement is to use the first two columns at APQP-2 and APQP-4. The APQP-3 report is generated during the
first parts off run at the supplier's manufacturing location. This establishes a baseline performance on the process in its
"as received" state. The APQP-4 report is generated at the time product is manufactured for the PPAP submission. Theadditional columns would either be used at the discretion of the SDE or based on circumstances that require additional
reviews.
Supply Chain Map
Example
An example of how a Supply Chain Map may appear for a typical metal component.
Date: 14 May, 2008
Revision: A
Magna Electronics APQP WorkbookProcess Owner/Department:
Chris Hempsall
Approved by:
Justin Reaume
-
7/23/2019 APQP Workbook
3/20
Part No.: Date: ________________
Rev. No.:
YES NO
ll
l
l
l
Conclusion:
Feasible
Feasible (Conditional)
Not Feasible > Design revision required to produce product within the specified requirements.
Issue # Open Close
Name: Name:
Title: Title:Signature:
Date: Date:
Name: Name:
Title: Title:
Date: Date:
Considerations
Is the product adequately defined (application requirements, etc.) to enable feasibility evaluation ?
Can Engineering Performance Specifications be met as written?
Review Considerations:
Supplier Design Review Sign Off
Part Name:
Can product be manufactured without incurring any unusual:
Costs for capital equipment?Costs for tooling?
Alternative manufacturing methods?
Can product be manufactured to tolerances specified on drawing?
Can product be manufactured with Cpk's that meet requirements?
Is there adequate capacity to produce product?
Does the design allow the use of efficient material handling techniques?
Are Cpk's greater than 1.33?
Is the appropriate packaging available to protect the product during shipment? (Provide a proposal)
Are special / uncommon materials required that are not readily available?
> Product can be produced as specified with no revisions.
Is statistical process control required on product?
Is statistical process control presently used on similar products?
Where statistical process control is used on similar products:
Are the processes in control and stable?
Corrective Actions / Resolution Plan
Signature:
Sign-Offs:
Magna Electronics Supplier _____________________________
Signature: Signature:
ME and supplier product quality planning team has considered the following questions, not intended to be all-inclusive in performing a feasibility
evaluation. The drawings and / or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All
"no" answers are supported with attached comments identifying our concerns and proposed changes to enable us to meet the specified requirements.
> Changes recommended (see issues list below).
Issues / Comments / Risks
-
7/23/2019 APQP Workbook
4/20
02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
02
04
06
1.1 Design FMEA
1.2 Preliminary Capacity Study reviewed
1.3 Manufacturing Feasibility reviewed
1.4 Component Design Review
Product Characteristic Matrix initiated
1.5 Key Supplier Metrics initiated
1.6 Supplier Project timing plan
1.7 Open Issues Action Plan created
2.1 Measurement/ Testing equipment2.2 Preliminary Process Flow Chart Review
2.3 Preliminary PFMEA Review
2.4 Preliminary Control Plan Review
2.5 Tool ing
2.6 Capital equipment
2.7 Training
2.8 Process instructions
2.9 Packaging
2.10 Key Supplier Metrics reviewed
3.1 ELV/IMDS
3.2 Safe Launch Plan (PCM) finalized
3.3 Sub-Supplier PPAP Approvals
3.4 Supplier Ramp Plan
3.5 Plant Readiness Review3.6 Launch Readiness Audit
3.7 Appearance Approval Process (when applicable)
3.8 Key Supplier Metrics reviewed
4.1 PPAP
4.2 Launch Readiness Audit
4.3 Run at Rate
4.4 Key Supplier Metrics reviewed
4.5 OK to Launch Sign-Off
5.1
5.2
5.3
5.4
5.5
5.6
5.7
KEY: X Planned start O Planned completion + Act
Supplier APQP: Four Phase Time Line (EXAMPLE)
APQP
PHASE
OUTPUT
Year 1
3.
Pre
-PPAP
4.
Product/
Process
Validation&
5.
Other
Requirements
The Magna Electronics Supplier Advanced Product Quality Planning (APQP) process consists of 4 Phases. Essential to this process are 12 Key Supplier Metrics (KSM).
reviewed during each of the following phases. The time line below illustrates the relationship between the 4 Phases, their deliverables and the Global Development & Prod
This workbook consists of 9 forms in support of this process (the respective tab colors are highlighted in "yellow"). Suppliers are expected to use this process regardless oa PPAP package.
1.
SupplierKick-Off
2.
Product/Production
Realization
Magna Electronics APQP Workbook
-
7/23/2019 APQP Workbook
5/20
02 04 06 08 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 02 04 06 0 8
1.1 Design FMEA
1.2 Preliminary Capacity Study reviewed
1.3 Manufacturing Feasibility reviewed
1.4 Component Design Review
Product Characteristic Matrix initiated
1.5 Key Supplier Metrics initiated
1.6 Supplier Project timing plan
1.7 Open Issues Action Plan created
2.1 Measurement/ Testing equipment
2.2 Preliminary Process Flow Chart Review
2.3 Preliminary PFMEA Review
2.4 Preliminary Control Plan Review
2.5 Tool ing2.6 Capital equipment
2.7 Training
2.8 Process instructions
2.9 Packaging
2.10 Key Supplier Metrics reviewed
3.1 ELV/IMDS
3.2 Safe Launch Plan (PCM) finalized
3.3 Sub-Supplier PPAP Approvals
3.4 Supplier Ramp Plan
3.5 Plant Readiness Review
3.6 Launch Readiness Audit
3.7 Appearance Approval Process (when applicable)
3.8 Key Supplier Metrics reviewed
4.1 PPAP
4.2 Launch Readiness Audit
4.3 Run at Rate
4.4 Key Supplier Metrics reviewed
4.5 OK to Launch Sign-Off
5.1
5.2
5.3
5.4
5.5
5.6
5.7
KEY: X Planned start O Planned completion + Actu
5.
Other
Requirements
3.
Pre-PPAP
4.
Product/
Process
Validation
&
1.
SupplierKick-Off
2.
Product/Pr
oduction
Realization
Supplier APQP: Blank Time Line
AP
QP
PHASE
OUTPUT
Year 1
-
7/23/2019 APQP Workbook
6/20
Enter the number ofGREEN elements at
the time of the report.
Enter the total number of elements being
tracked. There are 34 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.
Enter number of completed processinstructions at the time of the review.
Enter total number of process instructions
needed for serial production.
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 amount of available capacity at the
time of the review. Enter result as a
decimal number.
The minimum amount of available capacityshould be 15% (85% utilization). Enter
0.15
Enter the number of characteristics, with
a Ppk > 1.67, at the time of the review.
Enter the total number of designated
characteristics on the drawing.
This is the total number of samples that
passed all of the required testing at the
time of the review.
The should represent the total number of
individual tests required times the number
of samples, for each test, that is required.
Total number of set-up, manufacturingand inspection instructions needed.
Process Efficiency Measured in available capacity.
Expectation for open capacity is 15%
minimum. This is achieved by dividing
Takt time into cycle time and subtractingthe result from 1.
Results
APQP Readiness
DefinitionMetric
Data is derived from the 'APQP Progress
Report'. This metric tracks the
percentage ofGREEN elements
compared to the total number of
elements being tracked.
Process Instructions
APQP: Key Supplier Metrics Operational Definitions
First time Capability Percentage of good parts to the total
number of parts produced during the Run
at Rate.
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
of the number of unique tests multiplied
by the number of samples required for
the test.
This section defines the Key Supplier Metrics that will be tracked throughout the four APQP Phases. Reviews will be held toward the end of each of the four
phases. Review of these metrics, in the Phase 4, will take place before the final full PPAP approval
Process Capabil ity The number of designated
characteristics with a Ppk > 1.67.
Goal
-
7/23/2019 APQP Workbook
7/20
Results
DefinitionMetric
APQP: Key Supplier Metrics Operational Definitions
This section defines the Key Supplier Metrics that will be tracked throughout the four APQP Phases. Reviews will be held toward the end of each of the four
phases. Review of these metrics, in the Phase 4, will take place before the final full PPAP approval
Goal
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. Interim 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
5. Fully implemented process; No deviation
or concession required.
The score achieved on the Launch
Readiness Audit. Enter data as a
decimal number.
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 number of approved sub-component
and materials making up the shipped
component/material.
The number of elements (or documents)
completed for the PPAP package at the
time of the review.
The total number of required elements, or
documents, required to be submitted.
PPAP Package
Completion
Number of PPAP submission package
elements completed compared to
required number.
Launch Readiness Audit
This metric assesses the level of
implementation of the full production
intent process. Processes that are not
fully implemented at the Start-of-
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 non-
conformances from reaching MEI.
Process Implementation -
% Completed
Sub-Component PPAP
Approvals
Number PPAPs approved for the
purchased sub-components and
materials that makes up the final shipped
component/material, and that do not have
any deviations, waivers, and/or
concessions granted by any tier below
MEI.
A comprehensive audit tool's score,
which assesses a process's state of
preparation to meet serial production
requirements.
-
7/23/2019 APQP Workbook
8/20
Results
DefinitionMetric
APQP: Key Supplier Metrics Operational Definitions
This section defines the Key Supplier Metrics that will be tracked throughout the four APQP Phases. Reviews will be held toward the end of each of the four
phases. Review of these metrics, in the Phase 4, will take place before the final full PPAP approval
Goal
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 orhas 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 andhas 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.
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.
Completion of the PCM is noted by
Operations, i.e., plant, approval of the
Safe Launch Plan portion of the form.
Stages of completion are:
1. MEI's supplier has completed the
form, less SLP.
2. MEI's supplier has completed their
sub-supplier form, less SLP.
3. Supplier section completed, including
SLP.
4. Sub-supplier section completed,
including SLP.
5. Characteristic Review signed off on
both tabs.
6. Complete sign-off on both tabs for
"Safe Launch Exit Approval.
Supplier Ramp Plan
Safe Launch Plan (PCM)
Deployment
This element evaluates a supplier's ability
to meet ramp-up timing and volumes.
-
7/23/2019 APQP Workbook
9/20
Supplier Name: Supplier Location: Supplier Code:
Part Number: Part Name: Revision Level:
Component Priority Level: Lead Customer/Program: Report Date:
SUPPLIER SIGN-OFF (MANAGER LEVEL)
MEI SIGN-0FF
Results
#DIV
Goal
TargetProduction Preparation Influencing Factors
Number of PPAP required documents required
Complete Stage 5 by SOP 5
Primary Indicator:
Enter completed stage of PCM (see comments)
Total number of instructions completed
Ramp planned completed and shipping to releases
Available capacity based on % of cycle time to Takt time
achieved
Maximum acceptable % of available capacity base on %cycle
time to Takt time
Total number of purchased sub-components/materials
State of completed supplier ramp plan
Number of PPAP required documents completed
Total number of elements from 'Progress Report'
Number of sub-components and materials PPAP approved
Number of capable designated characteristics features
Score achieved during event
Goal is 100%.
1. APQP Readiness
2. Process Instructions
6. Test AchievementNumber of tests passed
7. Process Implementation -
% Completed
% of total tests
Number of 'Progress Report' elements with Green status
5
MANUFACTURABILITY
Total number of designated characteristics features
Results from Run at Rate
Ideal % of good parts3. First Time Capability
Total number of instructions needed.
Production volumes provided off production intent process
High volume process or Interim Process wi th Concession
5
Production ControlPurch/Sales Quality DesignEngineering
#DIV/0!Metrics Overall Score #DIV/0! #DIV/0!
Signature
Name (print)
9. Sub-Component PPAP
Approvals
10. PPAP Package
Completion
11. Supplier Ramp Plan
Man
8. Launch Readiness Audit
5. Process Capability
12. Safe Launch Plan (PCM)
Deployment
MEI Internal Use only Commodity Mgr/Buyer
SDE
SQA
Function Project Leader
DLN
K
E
Y
M
E
A
S
U
R
E
A
B
L
E
S PPAP
Supplier APQP: Key Supplier Metrics Report
Signature
Signature
Name (print)
Name (print)
Name (print)
Signature
4. Process Efficiency
-
7/23/2019 APQP Workbook
10/20
Precision Forming
Amarrillo, TX
Airbag Reaction Can
49019804A
Stamping body, end
caps, brackets
TIER 4
SUPPLIER
TIER 2
SUPPLIER
TIER 3
SUPPLIER
Anaconda Steel
Erie, PA
C1038 Rod
Steel Mill
Zephyr Coatings
Austin, TX
E-Coat
Dynamic Chemical
Supplies
Tulsa, OK
Coating materials,
solvents
White & Jones
Jackson, MI
C1038 Rod
Wire Draw, Anneal
Fine Fasteners, Inc.
Benton Harbor, MI
M8x20 Weld Stud
59039813A
Cold Forming
B&C Processing
Georgetown, PA
C1024 RodWire Draw, Anneal
ABC Nut Co.
Summit, NJ
M8x15 Staking Nut
59039812C
Cold Forming
AAA Heat Treat
Frederick, MD
Harden & Draw
Kojak Heat Treat
Benton Harbor, MI
Harden & Draw
Supplier APQP: Supply Chain Map - Example
TIER 1 SUPPLIER
Pacific Steel
Los Angeles, CA
C1024 RodSteel Mill
-
7/23/2019 APQP Workbook
11/20
Supplier: Part Number: Date: Revision:
TierTier IIME Receiving
Operation
OEM
Customer
upplier APQP: Supply Chain Map
Tier V Tier IV Tier III
-
7/23/2019 APQP Workbook
12/20
Part Name: Supplier
Part Number/ Revision: Lo
Project/ Program: MEI Using P
Design CharacteristicLevel/
Class
DFMEA
Sev.
PFMEA
Occ.
PFMEA
Det.RPN Control Method/ Equipment
Date
MEI SDE
MEI Plant SQA
Supplier Representative
Date
MEI SDE
MEI Plant SQA
Ch
#
MEI/ Supplier
Name
Name
Position/ Title
Supplier Representative
Position/ Title
TIER II - S
Supplier APQP: Product Characteristic Matrix
-
7/23/2019 APQP Workbook
13/20
Part Name: Supplier Name:
Part Number/ Revision: Location:
Project/ Program: MEI Using Plant(s):
Design CharacteristicLevel/
Class
DFMEA
Severity
PFMEA
Occurrence
PFMEA
DetectionRPN Control Method/ Equipment
Gauge
R&R
% Tol
Pp/ Ppk Freq./Size Con
Date
MEI SDE
MEI Plant SQA
Supplier Representative
Date
MEI SDEMEI Plant SQA
Sub-Supplier Process Control
Signature
Signature
Position/ Title
Supplier Representative
Position/ Title
Safe Launch Exit A pprovals
Character ist ic Review Ap proval
#
TRW/ Supplier
Name
Name
Supplier APQP: Product Characteristic Matrix (Sub-Supplier)
-
7/23/2019 APQP Workbook
14/20
Total WEEK W14
71 Incidents 65
9350 QTY 2350
7594 PPM 27660
FaultNo.
Failure Mode Total Action Timing W14
13 Abutment hole diameter 11 11
2 Lining wear inspection hole diameter 10 10
14 Nut thread check 7 7
8 Wheel cylinder hole position 6 6
3 Adjuster hole diameter 5 5
6 Bearing case ID 5 5
7 Wheel cylinder hole diameter 5 5
5 Mounting holes diameter 4 4
9 Brake cable hole position 3 3
11 Threaded nut hole position 3 321 NO paint scratch and or contamination, Blistering, runs 2 2
12 Abutment hole position 2 2
20 No Cracks on backplate (visual boundary sample) 2 2
16 Abutment and locating plate gap 0 0
10 Brake cable hole diameter 0 0
19 Locating abutment plate smooth surface 0 0
17 Dust ring gap to backplate check 0 0
18 Cable guide gap 0 0
4 Mounting holes position 0 0
15 Nut weld torque 0 0
1 Hold down pin diameter 0 0
Safe Launch Plan: Weekly QOS Report
0
5000
10000
15000
20000
25000
30000
0
10
20
30
40
50
60
70
W14 W15 W16 W17 W18 W19 W20 W21 W22 W23 W24 W25 W26 W27 W28 W29
Incident
Touch Point Incident & PPM Monitoring
Incidents PPM
Example
-
7/23/2019 APQP Workbook
15/20
Supplier Name: Component Manufacturing Location: Supplier Code:
MEI Part Number(s): Issued by:
Customer Name: Customer Platform: MEI Product: Status:
Action plan review
Distribution:
Status
Da
Launch ActivityLaunch Activity Date Date Launch Activity Date
Source of IssueConcern / Problem / Open Issue
Description
Dates
Date scheduled Date actual
DueOpened
Supplier APQP: Open Issues - Corrective Action Plan
Item
NumberAction
Closed
-
7/23/2019 APQP Workbook
16/20
Supplier Name: Supplier Location: Supplier Code:
Part Number: Part Name: Revision Level:
Component Priority Level: Lead Customer/Program: Report Date:
PROGRAM MILESTONES
PHASE/ELEMENT STATUS OVERVIEW
20
40
60
80
100
3.3 Supplier Ramp Plan
Key Supplier Metrics reviewed
3.6Appearance Approval Process
(when applicable)
3.4
Packaging
3.5 Launch Readiness Audit
APQP
PhaseStatus
Element Issues / Recovery Plan
DatePercent
Complete
Needed Committed Complete
Manufacturing Feasibility reviewed
C
PPAP submission
Start of Production
ME PV Build
1
3
Date Date
CommittedEvent Event
Design Freeze
Needed Committed Completed Needed
4
Design FMEA
Preliminary Capacity Study
reviewed
2
First Off-Tool
Capital equipment
Measurement/ Testing equipment
Key Supplier Metrics initiated
Supplier Project timing plan
Open Issues Action Plan created
First Off-Process
PPAP
Launch Readiness Audit
Key Supplier Metrics reviewed
ELV/IMDS
Safe Launch Plan finalized
Plant Readiness Review
2.3
Run at Rate
OK to Launch Sign-Off
1.1
1.2
1.3
1.5
1.6
1.7
Key Supplier Metrics reviewed
3.1
3.2
2.12
2.11
2.1
2.2
2.4
2.9
2.5
2.7
Component Design Review
4.5
3.7
4.1
4.2
4.3
4.4
2.1
2.13
Training
Process instructions
Supplier APQP: Progress Report - Status Overview
1.4
Sub-Supplier PPAPs
Launch Readiness Audit
Tooling
Initiate PCM (Safe Launch Plan)
2.6 Process Flow Diagram
2.8 Control Plan
PFMEA
-
7/23/2019 APQP Workbook
17/20
Magna Part Number: Description: Revision Level:
Customer: Program: Product Line:
Company Name: Product Line:
Company Location: Using Location:
Supplier Code: Reviewer:
Contact Name: Phone: Review Date:
Contact email: Disposition:
No. 1 2 3 4 5
1 S S S S R
A.
B.
C.
D.
1.
2.
3.
E.
F.1.
G.
H.
1.
2.
I.
J.
2 R S S * R
A.
B.
3 R S S * R
A.
B.C.
D.
E.
4 R R S * R
A.
5 R R S * R
A.
B.
C.
D.
6 R R S * R
A.B.
C.
7 R R S * R
A.
B.
C.
D.
E.
8 R S S * R
PPAP Submission Checklist
SUPPLIER INFORMATION MAGNA ELECTRONICS INFORMAT
Document
Part Submission Warrant
PART NUMBER INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
WEIGHT INCLUDED
SUPPLIER MANUFACTURING INFORMATION COMPLETE, INCLUDING SUPPLIER CODE
PPAP
Submission
Level
A
Required
ELV/IMDS INFORMATION INCLUDED: The Magna Holly IMDS # is 9822
CORRECT REASON FOR SUBMISSION BOX CHECKEDIF OTHER IS CHECKED, THAT THE CORRECT REASON FOR SUBMISSION IS NOTED
CORRECT SUBMISSION LEVEL BOX IS CHECKED
SUBMISSION INFORMATION COMPLETE.
ALL APPROPRIATE BOXES CHECKED
BUYER NAME INCLUDED
APPLICATION INFORMATION INCLUDES MAGNA CUSTOMER AND PROGRAM
SIGNATURE AREA IS COMPLETED AND CONTAINS ALL INFORMATION
Design Records (Drawings, Specifications)
A MARKED OR BALLOONED DRAWING IS ATTACHED. Note: All non reference print items and specs must be addressed.
COPIES OF ALL REFERENCED SPECIFICATIONS ARE INCLUDED IN THE SUBMISSION (LEVEL 3 ONLY)
THE SUBMISSION RESULTS AREA IS PROPERLY FILLED OUT AND THE PACKAGE REFLECTS THIS
PACKAGE CONTENTS MUST REFLECT SUPPLIER'S STATEMENT OF COMPLIANCE
FOR MULTIPLE TOOLS/CAVITIES/PROCESSES THAT THE INFORMATION IS NOTED IF APPLICABLE
THE DECLARATION AREA CONTAINS THE RUN AT RATE INFORMATION
ACTION PLAN INCLUDED IF REQUEST IS FOR DEVIATION/CONCESSION
SIGNED AND DATED BY MAGNA ENGINEERING
Customer Engineering Approval Documents
IF PROCESS INCORPORATES UNRELEASED CHANGE, COPY OF ENGINEERING DOCUMENT INCLUDED
Change Documents
PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
PART APPLICATION / PROGRAM / PLANTS IDENTIFIEDSPECIFIES TIME SPAN OR VOLUME AFFECTED
AREAS OF CONCERN IDENTIFIED IN THE DFMEA ARE CARRIED OVER INTO THE PFMEA.
Process Flow Diagram
PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECTMUST START WITH RECEIVING AND FINISH WITH SHIPMENT OF MATERIAL
Design FMEA
PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART?
DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT?
WHERE APPROPRIATE, DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT?
ARE CONCERNS INCLUDED THAT WERE DISCOVERED IN EARLY STAGES?
CRITICAL FEATURES IDENTIFIED ON THE PCM/SLP, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS,
CRITICAL PROCESS CONTROLS, ETC.) ARE INCLUDED IN THE PFMEA AND HAVE RPN CALCULATED.
PROCESS FLOW DIAGRAM IS ACCURATE
Process FMEA
PART NUMBER LEVEL INCLUDED, CURRENT AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART?
Dimensional Results
PPAP Level 3 Unless MEI SDE directs "other"
-
7/23/2019 APQP Workbook
18/20
A.
B.
C.
D.
E.
F.
G.
11 R R S * R
A.
B.
C.
D.
E.
F.
12 R S S * R
A.
B.
13 R R S * R
A.
B.
C.
D.
E.
F.
G.
14 S S S * R
15 R R R * R
16 R S S * R
17 R R R * R18 R R S * R
19 R R S * R
A.
20 * * S * *
A.
B.
C.
D.
E.21 * * S * *
22 R R S * R
23 * * S * *
A.
B.
24 S S S S R
A.
B.
25 S S S S R
A.
26 * * S S R
A.
CAPABILITY STUDY RESULTS ARE SUBMITTED ON THE PRODUCT CHARACTERISTICS MATRIX
PPK's FOR ALL CHARACTERISTICS ARE GREATER THAN, OR EQUAL TO, 1.67.
IF NO, A WRITTEN CORRECTIVE ACTION STATEMENT, FOR EACH, IS INCLUDED AND CONTAINMENT, WHEN
FEASIBLE, IS 100% INSPECTION.
RAW DATA IS INCLUDED FOR EACH STUDY
(per MAGNA XXX)
STUDIES ARE CONDUCTED FOR ALL CRITICAL AND SIGNIFICANT CHARACTERISTICS (EXCEPT DIMENSIONS
WITH BONUS TOLERANCES). EACH STUDY MUST INCLUDE THE STUDY DATE.
TEN (10) MEASUREMENTS FOR BONUS TOLERANCE DIMENSIONS ARE INCLUDED or PER MAGNA SDE DIRECTION
WRITTEN CORRECTIVE ACTIONS ARE INCLUDED FOR GAGE R&R'S GREATER THAN 30%.
THREE (3) OPERATORS, THREE (3) TRIALS ARE UTILIZED.
FORMS ARE COMPLETELY FILLED OUT.
WAS THE PROCESS CAPABILITY CALCULATED MADE OFF PARTS MADE FOR PPAP SUBMISSION?
PROCESS AVERAGES MATCH FOR MULTIPLE CAVITIES, DIES AND TOOL PROCESSES.
Measurement Systems Analysis (Gage R&R)
STUDIES ARE INCLUDED (AND DATED) FOR GAGES USED TO MEASURE SIGNIFICANT AND CRITICAL DIMENSIONS.
GAGE R& R FORM IS USED FROM MEASUREMENT ANALYSIS HANDBOOK.
PART NUMBER LEVEL INCLUDED AND CORRECT. REVISION LEVEL INCLUDED AND CORRECT
DOES CONTROL PLAN REFLECTS LAUNCH PRACTICE ITEMS?
DOES IT SHOW SAME REVISION LEVEL AS PFMEA?
CONTROL PLAN ADDRESSES ALL SIGNIFICANT AND CRITICAL DIMENSIONS.
Qualified Laboratory Documentation
CERTIFICATE OF ACCREDITATION IS FROM A NATIONALLY RECOGNIZED ORGANIZATION.
SCOPE OF ACCREDITATION IS INCLUDED.
Control Plan
Appearance Approval Report (As Appropriate)
Bulk Materials Requirement Checklist (As Appropriate)
Sample Product
Master Sample
CONTROL PLAN ADDRESSES THE ENTIRE PROCESS FROM RECEIPT OF MATERIAL TO SHIPPING PRODUCT.
CONTROL PLAN INCLUDES ANNUAL REVALIDATION REQUIREMENTS.
CRITICAL FEATURES IDENTIFIED ON THE PCM, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS, CRITICAL
PROCESS CONTROLS, ETC.) ARE INCLUDED IN THE PFMEA AND HAVE RPN CALCULATED.
Product Characteristic Matrix (per MAGNA XXX)
ALL SUB-TIER SUPPLIERS HAVE BEEN INCLUDED BASED ON SUPPLY CHAIN MAP.
ALL SIGNIFICANT AND CRITICAL DIMENSIONS ARE INCLUDED, AND FOLLOW BACK TO THE MANUFACTURING
PROCESS THAT PRODUCES THEM.
Checking Aids
Compliance with Customer Specific Requirements
DOCUMENT(S) DEMONSTRATING COMPLIANCE WITH ANY OEM SPECIFIC COMMUNICATED REQUIREMENTS.
Additional MAGNA SPECIFICPPAP Requirements
Packaging Plan and Sample Label (per MAGNA XXX)
RUN-AT-RATE or Capacity Verification per MAGNA SDE DIRECTION (per MAGNA XXX)
DOES THE SUPPLIER NEED TO INCREASE THEIR CAPACITY?
ARE BOTTLENECKS IDENTIFIED AND RESOLVED? ARE THERE ANY TOOLING CONSTRAINTS?
PFMEA RPN'S ARE INCLUDED FOR ALL INCLUDED DIMENSIONS.
CUSTOMER TOUCH POINTS AND CRITICAL PROCESS CONTROLLED DIMENSIONS ARE INCLUDED.
SAFE LAUNCH PLAN DOCUMENTS CONTROLS THROUGHOUT THE SUPPLY CHAIN UP TO MAGNA.
Evidence of ELV / IMDS Approval
APPLIES ONLY TO SUPPLIERS TO FOR WHICH THE COMMERCIAL SITUATION DOES NOT ALLOW
FOR FULL DISCLOSURE.
Critical process approval (Heat treat, plating)
ARE THERE ANY CRITICAL SECONDARY PROCESSED THAT REQUIRES USE OF A RECOMMENDED SUPPLIER OR AMAGNA AUDIT BEFORE THEY ARE USED?
Certification of Review** (per MAGNA XXX)
Sub - contractor PPAP status
IS THERE A PSW FOR EACH COMPONENT AND MATERIAL IDENTIFIED IN THE BOM AND OR PCM?
ARE THE PSW'S FULLY APPROVED? IF NOT, IS THERE A MAGNA DEVIATION/CONCESSION FOR EACH PSW NOT
FULLY APPROVED?
-
7/23/2019 APQP Workbook
19/20
Instructions: For the submission of each Part Number, please utilize the MEI PPAP Checklist and insert the appropriate
PPAP document into its respective folder within the Zip File Master. If a document is not relevant/required, submit
an insert that notes that that element is not applicable. Examples are often AARs and DFMEAs.
PPAP Submission Folder
-
7/23/2019 APQP Workbook
20/20
Function Functio
NameDept.
Tel.
Fax.
E-mail
Address/
Location
Name
Dept.
Tel.
Fax.
E-mail
Address/
Location
Name
Dept.
Tel.
Fax.
E-mail
Address/
Location
Name
Dept.
Tel.
Fax.
E-mail
Address/
Location
Name
Dept.Tel.
Fax.
E-mail
Address/
Location
Name
Dept.
Tel.
Fax.
E-mail
Address/
Location
Name
Dept.Tel.
Fax.
E-mail
Address/
Location
Chris Hempsall
Purchasing
810-603-4137
Project Management
MEI Receiving Plant
Quality
MEI Receiving Plant
Logistic & Packaging
MEI Engineering
MEI Purchasing
Program Buyer
Contact Information
MEI Purchasing
Commodity Buyer
MEI APQP: Contacts- APQP TEAM
MEI Supplier
Development
Engineering
mailto:[email protected]:[email protected]