AdvancedProductQuality

PlanningADVANCED PRODUCT QUALITY PLANNING

INSTRUCTIONAL PRESENTATION – MIKE RIZUTORev 6.1

APQP/PDPTHE POLARIS DEVELOPMENT PROCESS SHALL INCLUDE

ADVANCED PRODUCT QUALITY PLANNING

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Lack of collaboration is a major risk Late engagement is a risk

How much is new? How much time? How many resources?

Design Collaboration Process Collaboration

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= AdvancedLet’s start early,

with the concepts and collaboration

= ProductThis is what the

customer is requesting

= QualityLet’s get it right the first time, efficiently

and every time = Planning

Through Collaboration we’ll

create a robust plan

Structured collaboration involving Engineering, Manufacturing, Material Control, Purchasing, Quality, Sales and Management from both Polaris and the Supplier

INPUT!

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Advanced Product Quality Planning is a structured method of defining and

establishing the steps necessary to assure that a product satisfies the customer

Sometimes Referred to as Moving the MountainRev 6.1

The AIAG Advanced Product Quality Planning (APQP) and Control Plan Reference Manual [available at aiag.org] provides the general guidelines for ensuring that APQP is implemented in accordance with the requirements of the customer. The APQP spreadsheet used by Polaris includes the corresponding page number referencing each of the APQP steps for quick orientation.

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The APQP/PDP Spreadsheet acts as

both a workbook and project tracker

Relevant product information is entered

Cross functional teams are established

Individual tasks are selected and assigned

Time lines are managed by date, responsibility, and

percent of completion

Documentation relative to the project

is stored

Overall APQP/PDP performance/progress

is reported

Here is where progress is

recorded and stored

The Spreadsheet

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Risk is determined by several factors:•Time to resource•New product•New supplier•Design risks• Safety critical•Technically complex• Supplier assessment score• Supplier performance (history)

The Polaris Risk Assessment considers the factors and selects whether the

APQP/PDP workbook will be level 1, 2 or 3

Each level will have a minimum number of APQP steps assigned

required to be completed by both Polaris and the Supplier

There are 63 possible steps to select on the APQP/PDP spreadsheet. These steps are selected by all or part of both

cross functional teams. Based on project risk, Polaris has 3 levels of APQP/PDP with

minimum required steps preselected.

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Level 1 – Low Risk

• 21 Mandatory APQP Steps SelectedLevel 2 –

Medium Risk

• 28 Mandatory APQP Steps SelectedLevel 3 –

High Risk

• 39 Mandatory APQP Steps Selected

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.00.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

Risk Assessment

PII Impact

Com

mod

ity R

isk

These are minimum APQP requirements as determined by Polaris, other value added APQP steps may be selected by the Supplier/Polaris cross functional teams

When saving APQP/PDP workbooks please use the naming convention of:project name_supplier_part number

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There are 5 PDP Gates/Milestones

total

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• The tabs at the bottom of the workbook are hyperlinked to the steps on the APQP sheet

• Information on APQP and sometimes sample forms are located on these tabs

• The tabs should also be used to convey information related to the selected step

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• The tabs at the bottom of the workbook are hyperlinked to the steps on the APQP sheet• Information on APQP and sometimes sample forms are located on these tabs• The tabs should also be used to convey information related to the selected step• Marked up drawings for 2.2 DFM&A, completed 2.13 MFC, completed Packaging Approval Form

are a few examples of items which should be attached to the workbook• Larger items such as PFMEAs and Control Plans we ask that upon completion the first page of the

document be placed on the corresponding tab and the full copy sent to the SQE for review

One of the many advantages of APQP is PPAP related documents, which have to be submitted before the PPAP due date, can be preapproved by Polaris ahead of

time by obtaining a GOLD square

The Polaris SQE is saying, “This document is ready

for PPAP submission”

PDP Status Tab of Workbook

Provides a Snapshot of

PDP Progress by the Supplier

Populated from APQP Spreadsheet

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Data Derived from the Supplier PDP Status is Used to

Report Overall PDP Project Status

Across Multiple Suppliers

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SQE’s issue the APQP/PDP Workbook to our Suppliers. When the Supplier utilizes the Workbook Project PDP reporting is automatically reported by Supplier and by

Project to our Management Group.

RECAP• The APQP Spreadsheet acts as both a workbook and project tracker

• Relevant product information is entered

• Cross functional teams are established

• Individual tasks are selected and assigned

• Time lines are managed by date, responsibility, and percent of completion

• Documentation relative to the project is stored

• Overall APQP performance/progress is reported

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