Prioritizing Quality Deliverables for NPI

PPAP/APQP
 Advanced Product Quality Planning (APQP) Overview

Owner: DVP&R
Product Design and DFMEA
Engineering Prototype
Development Special Char.
Quality Control Plan
(YC / YS)

Owner:
Manufacturing
Process Design and PFMEA DFMA Pre-launch
Special Char. Process Control
Quality Development
(CC / SC) Flow Plan

Owner: Product and Process Validation

Manufacturing Production
Trial Run MSA / SPC
Quality Control Plan

Production
Owner:
Supplier Quality PPAP

Feedback Assessment & Correction Action

2
Advanced Product Quality Planning Working Level Process
Start

DFMEA ENG Responsible

Step One
ENG/EQ EQ Reviewed
YC/YS

ME Supplier
In-house Outsourced
Step Two
SQE
Supplier/ PE

CC/SC DWGs

PFMEA
Step
SQE
Three
Supplier/PE Control Plan 3
 Special Characteristics Defined
What are YC / YS Characteristics?
These are Potential Special Characteristics that derive from the DFMEA

Critical Characteristic (YC) = Severity 9-10. Potential CC.

Significant Characteristics(YS) = Severity 5-8 and Occurrence = 4-10. Potential SC.

What are CC / SC Characteristics?

These are Identified Critical (CC) and Significant (SC) characteristics that should be marked on
the drawing, and reviewed in the PFMEA and control plan.

Critical Characteristic (CC) = Severity 9-10.

Significant Characteristics(SC) = Severity 5-8 and Occurrence = 4-10.

4
FMEA Chart Rating for Severity, Occurrence and Detection

5
AIAG FMEA Standard VDA 4 German FMEA Automotive Standard
SxO RPN
International Reference FMEA Standards
Potential Critical Characteristic (YC To CC)
Severity 9-10
AIAG FMEA Standard

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Potential Significant Characteristic (YS to SC)
Severity 5-8, Occurrence 4-10
AIAG FMEA Standard

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Alignment of Special Characteristics from DFMEA with PFMEA

YC / YS CC / SC

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Special Characteristics (CC/SC) Identified on the Drawing

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1 PPAP
1.1 Purpose
To provide the evidence that all customer engineering design record and specification requirements are
properly understood by the organization and that the process has the potential to produce product
consistently meeting these requirements during an actual production run at the quoted rate.

1.2 Submission Requirements

You must submit initial samples and a PPAP package to Quality Team in the following situations:

 Start of production of off-tool / off-process parts – typically in VP build cycle

 Engineering change, i.e. new part number or issue level

 Change of manufacturing process

 Change of optional material or construction method

 Change or additional manufacturing location

 Tool refurbishment or replacement

 After prolonged interruption of production (> 2 years)

You are not permitted to ship parts for series production until they have received PPAP approval.

PPAP activities follow the guidelines available through AIAG for PPAP, unless otherwise noted within
this manual.

1.3 Submission level

The submission level determines what documents and samples are required in the PPAP submission.
Generally submission should be to level 3, unless otherwise agreed by Quality Team.
 PPAP Submission Levels
Submission Level
Item
Requirements
No.
1 2 3
1 PSW Cover Sheet O O O
2 Number of samples per cavity 5 5 5
3 Measured weight of samples O O O
4 Proof of IMDS submission O O O
5 Drawing or copy of 3D master O O O
6 CQP * O O
7 CQP Inspection Form * O O
8 Part Quality History form   O O
9 Dimensional Results   O O
  - Uncoated dimensional results   * *
  - Sub-component dimensional results   * *
  - Process capability on agreed characteristics   * *
  - Surface roughness checks   * *
  - Cross-sections   * *
  - Others   * *
10 Material testing results   O O
  - Raw material chemical analysis   * *
  - Coating analysis   * *
11 Performance testing results   O O
  - Corrosion test results   * * O – Requirements for the appropriate submission level
  - Vibration test results   * * Δ – Cover sheet only - available for viewing at the supplier
  - Environmental test results   * * * – Where required
  - Reliability test results   * *
  - Odour test results   * *
  - Haptic test results   * *
  - Acoustic test results   * *
  - EMC test results   * *
  - Software test report   * *
12 Design approval, engineering release (if supplier drawn)   O O
13 Process flow chart   O O
14 Control Plan   O O
15 Part and process assessment matrices   O O
16 Proof of series production cycle time   O O
17 Design FMEA     Δ
18 Process FMEA     Δ
19 Inspection and test equipment capability study     O
20 Tools, fixtures and checking aids list     O
21 Assembly Bill of Materials showing approval status     *
Minimum Requirements for
Interim PPAP approval
PPAP approval Loop
Questions
 NIO P a rtne r AP QP P ha s e Re vie w Q-C05-B-01-02. Re v 1.0
KEY REFERENCE
Ele me nt

Phas e

EVIDENCE TO PRES ENT

Item

Phase 1

Phase 2

Phase 3

Phase 4
EXPECTATIONS DELIVERABLE DOCUMENTATI
BY S UPPLIER Re vie w Note s
S ON

1 Cus tome r Input Re quire me nts S tatus NA NA NA

RFQ package including

P artner unders tand clearly if they are des ign res pons ible, co- S tatements in S ORs or nomination letter
Phase S ORs and all other
1 1.1 1 des ign res pons ible or build-to-print. S cope of job c learly S cope of job
requirements or
regarding s cope of job for the s ourced NA NA NA
defined. commodity
nomination letter

Cus tomer requirements in RFQ clearly unders tood including

program timing, GT&C, NS R, engineering s pecs , quality S OR, P rogram timing and all RFQ package including P artner to s how RFQ packaging and evidence
Phase
1 1.2 1
manufacturing and s ervice requirements , packaging and work plans to fulfill RFQ S ORs and all other that thes e requirements are communicated NA NA NA
logis tics requirements etc. All requirements communicated requirements requirements and unders tood within P artner project team
within project team.

Phase Des ign goals received and communicated to related pers ons Des ign goal deployment P artner leader des igner and des ign team to
1 1.3 Engineering S OR NA NA NA
1
and unders tood. within project team demons trate

Phase Quality and re liability goals received and communicated to P artner to s how that all engineering
1 1.4 1
related pers ons and unders tood.
DV plan Engineering S OR
requirements are included in DV plan
NA NA NA

P artner manufacturing s ite ha s been identified. Crafts mans hip P artner to demons trate that all crafts mans hip
Phase Lis t of crafts mans hip
1 1.5 1 requirements received and communicated within P artner
requirements
NA requirements are lis ted and cons idered in NA NA NA
team. program

Warranty target
Phase Cus tomer warranty target communicated to related pers ons
1 1.6 1
and unders tood.
deployment within NIO NS R P artner to s how warranty target from NIO NA NA NA
project team

Commodity P P M
Phase Cus tomer commodity P P M target/Launch KP Is requirements target/Launch KP I P artner to s how the received commodity P P M
1 1.7 1
clear. deployment within
NA
target and launch KP Is
NA NA NA
project team

2 De s ign/Manufacturing Re vie w S tatus

2 2.1
Phase
1
Cros s -functional team organized (including engineering,
quality, proces s , production, logis tics etc) for the reviews .
Is s ues tracking mechanis m defined.
Des ign review team and
is s ue tracking
mechanis m
NA
P artner to s how des ign review team and is s ue
tracking lis t
NA NA NA
Supplier
2 2.2 Phase
1
Review frequency defined cons idering the program complexity
and s tatus

Review includes all cus tomer input requirements , as

P artner des ign review
plan

Des ign review input lis t

NA
P artner to s how des ign review plan and
evidence of meeting minutes

P artner to s how des ign review plan and

NA NA NA
Requirements
Manual
Phase
2 2.3 1
applicable Des ign review open is s ue
RFQ package
evidence of meeting minutes /open is s ues
NA NA NA

Review s hall include AP QP s tatus of internally and externally P artner to provide a lis t of s ub-partner and
Phase S ub-P artner timing plan
2 2.4 1 s ub-partner parts /s ys tems and all other affected AP QP
& open is s ues lis t
NA provide tracking info of s ub-partner AP QP NA NA NA
elements including timing plan and open is s ue lis t etc
P artner to s how a lis t of s tatutory requirement
2 2.5
Phase
1
Review s hall include s tatutory requirements , les s ons learned
including market feedback, warranty data.
DFMEA NA reviewed and market feedback and warranty NA NA NA July 2021
data reviewed
P artner to provide a preliminary BOM
Phase
2 2.6 1 P reliminary bill of material (BOM) initiated P reliminary BOM NA including all level of parts , quantity per NA NA NA
vehicle, material us ed, potential s uppliers etc

Phase Reviews performed as s cheduled and open is s ues tracked per Review plan and open P artner to s how the review plan and als o the
2 2.7 NA NA NA NA
2
is s ue tracking mechanis m is s ues lis t from review open is s ues lis t from each review

Phase Review includes all cus tomer input requirements , as P artner to s how that review input lis t has
2 2.8 Review input lis t RFQ package NA NA NA
2
applicable included all cus tomer requirements 1

P artner to provide a lis t of s ub-s uppliers and

Phase Review s hall include AP QP s tatus of internally and externally S ub-P artner timing
2 2.9 2
P artner parts /s ys tems a nd all other affected AP QP elements & open is s ues lis t
NA provide tracking info of s ubP artner AP QP NA NA NA
including timing plan and open is s ue lis t etc
 QUALITY
Quality Policy SCORE AVG AUDIT TEAM NOTES
0-4 0
* ISO 9001:2000 / Alternatives 0 Attained ISO9001/2? (ideally ISO9001:2000) If not, plan to achieve? Alternatives (UL/CSA/BABT) plus credit given for major customer approvals.
* Statement & Effectiveness 0 Is there a quality statement? How relevant, level of understanding through company and visibility through the working practices

Pro-Active Tools SCORE AVG

0-4 0
* FMEA 0 Are FMEA's used, who is involved, evidence of implementation of results. View examples
* Audits 0 Are Internal / External audit's conducted, by who, view documented examples and evidence of closure of actions raised.
* Reviews / Circles 0 Are Quality Circles / reviews used, who is involved (look for shop floor involvement), documented evidence of issues raised and implementation of actions.

Document Control SCORE AVG

0-4 0
* Drawings 0 Control / release of drawings, how achieved, how does EC process work
* Specifications 0 Control / release of specifications
* Work Instructions 0 How are drawings identified on work instructions, control and update process for WI's during EC

Process Document Control SCORE AVG

0-4 0
* Route Card 0 Is a route card used to track Wipe? Travels with product, level of detail included, ops, p/ns, rev level, inspection stages with sign-off, batch size, etc traceability possible? Randomly view in-process job sheets to validate.
* Work Instructions 0 WI's in place at each stage? In appropriate language and used or there for show? Content, clarity - visual or written presentation?
* Traceability 0 Is a system in place to allow historic traceability? How specific (to operator / part / stage / machine or just batch?)

Process Controls SCORE AVG

0-4 0
* SPC 0 Is SPC used? Should it be? Is it used effectively, in manufacturing and/or inspection, test operator understanding of principle & actual use of results to adjust process .
* Capability Studies 0 Are capability studies used, what Cpk targets are used, actions taken where targets not met, link to inspection frequency?
* Monitoring Equipment 0 In-process gauging used? How effective? Accuracy level sufficient? Setting and calibration, who, how - review records for key criteria.

Non-Conforming Material SCORE AVG

0-4 0
* Identification 0 How is NCM identified? How good is process of segregation at point of identification (part and/or batch?), control of rework / inspection of NCM
* Storage 0 Are NCMs stored away from other materials, who has access to area? Risk of mis-management?
* Corrective Actions 0 Corrective actions used in what situations: (supplier / customer / problem size & type / internal), review records, closed loop process? - test for re-occurrence following implementation of corrective action.

Operator Training SCORE AVG

0-4 0
* Special Needs / Plan 0 Standard training plan, special ops training plan, details included of detail of training for each operation. Cross training used? If so to what level, how much flexibility
* Qualification Records 0 Records type e.g. training matrix showing employees qualified for each operation. How qualified? Who maintains records,

Calibration SCORE AVG

0-4 0
* Identification System 0 How is equipment identified for calibration? Due date shown on equipment? Verify examples from shop floor, is system adequate to control, view examples of calibration failures and action taken as a result.
* Records 0 Does equipment indicate if calibrated. Who maintains records, how are items due for calibration flagged - reactive / proactive / manual?

Inspection Process SCORE AVG

0-4 0
* Receiving 0 Is receiving inspection effective, sampling plan & suitable equipment, actions taken if NCM found. What is checked - list of critical dimensions and/or previous problems?
* In-Process 0 Is in-process inspection effective, sampling plan & suitable equipment, actions taken if NCM found. Records of results or pass/fail? How are attribute defects identified
* Final 0 Final inspection / test. Coverage? customer driven checking criteria or internally generated? If so how?
* Effectiveness 0 Is process geared to zero defects. Does inspection simply filter out defects or is it used to proactively identify process variation
* Records 0 Records kept and for how long? Kept at customer request? Shipped with goods? Traceability?

Sub-Contractor Control SCORE AVG

0-4 0
* Approval Process 0 How are suppliers selected and approved. Review format of approval, depth, scope, who approves, conditions?
* Performance Measurement 0 How is supplier performance measured. Format, frequency, who sets standard? Metrics used, actions taken on poor performing suppliers. Review evidence
* Sub-Con Management 0 Who interfaces with suppliers on Quality / Engineering issues, authority level, skill and experience

Quality Targets SCORE AVG

0-4 0
* Performance v Target 0 What elements of quality are measured, who sets quality targets, actual performance against internal and customer performance targets
* Performance Awareness 0 Level to which quality performance relative to the target is published within the organisation
* McLaren Expectations 0 Are set targets and metrics used in line with McLaren DPPM and other expectations.

0
44
0%
 Quality Audit

Quality Policy SCORE AVG AUDIT TEAM NOTES

0-4 0
* ISO 9001:2000 / Alternatives 0 Attained ISO9001/2? (ideally ISO9001:2000) If not, plan to achieve? Alternatives (UL/CSA/BABT) plus credit given for major customer approvals.
* Statement & Effectiveness 0 Is there a quality statement? How relevant, level of understanding through company and visibility through the working practices

Pro-Active Tools SCORE AVG

0-4 0
* FMEA 0 Are FMEA's used, who is involved, evidence of implementation of results. View examples
* Audits 0 Are Internal / External audit's conducted, by who, view documented examples and evidence of closure of actions raised.
* Reviews / Circles 0 Are Quality Circles / reviews used, who is involved (look for shop floor involvement), documented evidence of issues raised and implementation of actions.

Document Control SCORE AVG

0-4 0
* Drawings 0 Control / release of drawings, how achieved, how does EC process work
* Specifications 0 Control / release of specifications
* Work Instructions 0 How are drawings identified on work instructions, control and update process for WI's during EC

Process Document Control SCORE AVG

0-4 0
* Route Card 0 Is a route card used to track Wipe? Travels with product, level of detail included, ops, p/ns, rev level, inspection stages with sign-off, batch size, etc traceability possible? Randomly view in-process job sheets to validate.
* Work Instructions 0 WI's in place at each stage? In appropriate language and used or there for show? Content, clarity - visual or written presentation?
* Traceability 0 Is a system in place to allow historic traceability? How specific (to operator / part / stage / machine or just batch?)

Process Controls SCORE AVG

0-4 0
* SPC 0 Is SPC used? Should it be? Is it used effectively, in manufacturing and/or inspection, test operator understanding of principle & actual use of results to adjust process .
* Capability Studies 0 Are capability studies used, what Cpk targets are used, actions taken where targets not met, link to inspection frequency?
* Monitoring Equipment 0 In-process gauging used? How effective? Accuracy level sufficient? Setting and calibration, who, how - review records for key criteria.
Non-Conforming Material SCORE AVG
0-4 0
* Identification 0 How is NCM identified? How good is process of segregation at point of identification (part and/or batch?), control of rework / inspection of NCM
* Storage 0 Are NCMs stored away from other materials, who has access to area? Risk of mis-management?
* Corrective Actions 0 Corrective actions used in what situations: (supplier / customer / problem size & type / internal), review records, closed loop process? - test for re-occurrence following implementation of corrective action.

Operator Training SCORE AVG

0-4 0
* Special Needs / Plan 0 Standard training plan, special ops training plan, details included of detail of training for each operation. Cross training used? If so to what level, how much flexibility
* Qualification Records 0 Records type e.g. training matrix showing employees qualified for each operation. How qualified? Who maintains records,

Calibration SCORE AVG

0-4 0
* Identification System 0 How is equipment identified for calibration? Due date shown on equipment? Verify examples from shop floor, is system adequate to control, view examples of calibration failures and action taken as a result.
* Records 0 Does equipment indicate if calibrated. Who maintains records, how are items due for calibration flagged - reactive / proactive / manual?

Inspection Process SCORE AVG

0-4 0
* Receiving 0 Is receiving inspection effective, sampling plan & suitable equipment, actions taken if NCM found. What is checked - list of critical dimensions and/or previous problems?
* In-Process 0 Is in-process inspection effective, sampling plan & suitable equipment, actions taken if NCM found. Records of results or pass/fail? How are attribute defects identified
* Final 0 Final inspection / test. Coverage? customer driven checking criteria or internally generated? If so how?
* Effectiveness 0 Is process geared to zero defects. Does inspection simply filter out defects or is it used to proactively identify process variation
* Records 0 Records kept and for how long? Kept at customer request? Shipped with goods? Traceability?

Sub-Contractor Control SCORE AVG

0-4 0
* Approval Process 0 How are suppliers selected and approved. Review format of approval, depth, scope, who approves, conditions?
* Performance Measurement 0 How is supplier performance measured. Format, frequency, who sets standard? Metrics used, actions taken on poor performing suppliers. Review evidence
* Sub-Con Management 0 Who interfaces with suppliers on Quality / Engineering issues, authority level, skill and experience

Quality Targets SCORE AVG

0-4 0
* Performance v Target 0 What elements of quality are measured, who sets quality targets, actual performance against internal and customer performance targets
* Performance Awareness 0 Level to which quality performance relative to the target is published within the organisation
* McLaren Expectations 0 Are set targets and metrics used in line with McLaren DPPM and other expectations.

0
44
0%