Apqp-en

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning A structured method of defining the steps (process) necessary to assure that a product satisfies the customer The goal of APQP is to facilitate communication with everyone involved to ensure that all required steps are completed on time. Effective APQP depends upon top management commitment and support to assure that customer satisfaction is achieved AIAG APQP & Ctrl Plan Reference Guide, Page 5 Advanced Product Quality Planning

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning ‘ Phase’ Inputs & Outputs Voice of the Customer Market Research Historical Warranty and Quality Information Team Experience Business Plan and Marketing Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Studies Customer Inputs Service Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support Phase 1 Phase 2 Outputs by Design Responsible Activity Outputs by Advanced Product Quality Planning Team Design FMEA DFM and DFA Design for Manufacturability Design for Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes New equipment, tooling and facilities requirements Special product and process characteristics Gage and testing equipment requirements Team feasibility commitment and management support Subcontractor build Supplier build Phase 3 Packaging Standards Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Think Critical Paths

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Inputs / Outputs - Phase 1 Voice of the Customer Market Research Historical Warranty and Quality Information Team Experience Business Plan and Marketing Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Studies Customer Inputs Service Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support Phase 1 Phase 1 Inputs Phase 1 Outputs (= Phase 2 Inputs)

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Inputs / Outputs - Phase 2 Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support Phase 2 Outputs by Design Responsible Activity Outputs by Advanced Product Quality Planning Team Design FMEA DFM and DFA Design for Manufacturability Design for Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes New equipment, tooling and facilities requirements Special product and process characteristics Gage and testing equipment requirements Team feasibility commitment and management support Subcontractor build Supplier build Phase 1 Outputs (Phase 2 Inputs) Phase 2 Outputs (Phase 3 Inputs)

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Inputs / Outputs - Phase 3 Outputs by Design Responsible Activity Outputs by Advanced Product Quality Planning Team Design FMEA DFM and DFA Design for Manufacturability Design for Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes New equipment, tooling and facilities requirements Special product and process characteristics Gage and testing equipment requirements Team feasibility commitment and management support Subcontractor build Supplier build Phase 3 Phase 3 Outputs (Phase 4 Inputs) Packaging Standards Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Phase 2 Outputs (Phase 3 Inputs) Phase 2 Design Activity Outputs Phase 2 APQP Team Outputs

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Inputs / Outputs - Phase 4 Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval (PPAP) Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-off Phase 4 Packaging Standards Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Phase 3 Outputs (Phase 4 Inputs) Phase 4 Outputs (Phase 5 Inputs)

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Inputs / Outputs - Phase 5 Reduced Variation Customer Satisfaction Delivery and Service Phase 5 Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval (PPAP) Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-off Phase 5 Outputs Phase 4 Outputs (Phase 5 Inputs)

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Voice of the Customer External and Internal Customers Stated , Real and Perceived Needs Cultural Needs Unintended Uses Functional Needs vs. Technical Features

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Market Research Customer interviews Customer questionnaires and surveys Marketing test and positioning reports New product quality and reliability studies Competitive product quality studies “ Things Gone Right” reports The following is a list of vehicle features. Please read the entire list and place an X next to those features of your new vehicle that you Particularly Like. Room & Comfort Interior Appearance Exterior Appearance Handling Things Gone Right

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Historical Warranty and Quality Information “ Things gone Wrong” reports Warranty reports Capability indicators Supplier plant internal quality reports Problem resolution reports Customer plant returns and rejections Field return product analysis Tell us about any troubles you have had with the vehicle. Mark a X in each box next to any item you have had trouble with. Exterior Paint Things Gone Wrong Steering & Handling

Framework for quality plan May place constraints on timing, cost, investment, positioning, R&D resources Strategy defines target customer, key sales points, key competitors SWOT Strengths Weaknesses Opportunities Threats Old vs. New How deep and how far to go Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Business Plan - Marketing Strategy

A requirement of QS 9000 para. 4.1 Provides inputs to establish performance targets Must address key process(es) Must be measurable Methods for successful benchmarking: Identify appropriate benchmark(s) Find reason for gap between your status and benchmark Develop a plan for closing gap, meeting or exceeding benchmark Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product - Process Benchmark Data

Assumptions Features Design Process concepts Technical innovations Advanced materials Reliability assessments New technology Document assumptions as part of project plan Utilize as inputs to plan Consider alternate paths in case assumptions do not play out Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product - Process Assumptions

Frequency of repairs or replacements within designated time period(s) Repair or Throw-away? LRU Level (Line Replaceability Unit) Long range reliability and/or durability tests Studies can be VERY costly and lengthy EDCTP (Environmental Design Criteria Test Plan) Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product Reliability Studies MTBF = Mean Time Between Failures MTBO = Mean Time Between Overhaul MTBR = Mean Time Between Replacement Durability Failures

Next users provide information about needs and expectations Possibility of previous conducted reviews and studies Used to develop measure of customer satisfaction Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Customer Inputs

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Inter-Relationships QOS FMEA FTA RFTA APQP DOE Process Improvement Control Plan SPC Tools 8-D Problem Solving Business Quality Objectives Problem Prevention QFD Special / Critical Characteristics Customer Specified Special / Critical Characteristics

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Relationships Customer Requirements DFMEA PFMEA Warrant Control Plan Structural Conceptual Warrant Sample PPAP Product Condition Time

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Typical Automotive Trilogy Development Process Flow Diagram (Includes ALL Processes) Process FMEA (On ALL Processes) Process Control Plan (Critical Processes from FMEA) Design FMEA (On Intended Use) APQP Timeline Some Elements may be Included On Critical Characteristics & Characteristic Control Issues Critical Characteristics & Failure Effects Issues CC Matrix Customer Requirements (drawing, RFQ, etc.), Your company’s internal design / process requirements

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Document Links Process Flow Chart Operation Number Product/Process Characteristic Incoming Sources of Variation (Variation Class) Work Instruction Operation Number PFMEA Operation Number Control Plan Operation Number Product/Process Characteristic Incoming Sources of Variation (Variation Class) The APQP manual cites these links. In some companies, these are not discrete documents . The intent is to ensure discrete documents match. Operation Number

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Document Critical Paths Process Flow Chart Provides inputs to the Process FMEA and may provide inputs to the work instruction. Work Instruction PFMEA Control Plan DFMEA May or may not identify an input to the Process FMEA Provides input to control plan based upon a risk analysis. Define All Critical / Special Characteristics

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Effects of Changing the Process FMEA PFMEA Change in Detection Change in Occurrence Change in Severity Work Instruction Design Change Control Plan And Or Other Action A change in the severity of the effect of a potential problem can only be effected through a design change. When making a change to a document, it is important to consider the effects of that change on other documents. Typically the engineering change system in a company and/or corrective action system ensures these occur. But this is not always the case. Review your company engineering change procedure / system and see if it does so.

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning A Corrective Action System These are some typical ‘checks’ in the automotive world in response to a corrective action. A change to any one document typically drives an Engineering Change where the engineering change system is used to ensure that changes to any one document ensures appropriate changes to others .

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product Specific FMEA Approach Process FMEA Brand spanking new, never before product. Brand spanking new Process FMEA developed. Production Life Year 1 Process FMEA Copy of process FMEA from a similar product Year 1 I do NOT recommend product specific FMEAs unless you really cannot segregate your products into families for some reason. FMEA revised in response to an 8-D investigation Year 2002 - “Q” Body Intake manifold Year 2003 - “Q” Body Intake manifold Year 2 FMEA revised in response to an 8-D investigation FMEA revised in response to an 8-D investigation FMEA revised in response to an 8-D investigation

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Current Control Plans & FMEAs A Technology/Family Control Plan / Device FMEA follows an entire flow for a ‘ technology ’ through a defined entity. This is in contrast with a ‘process’ flow where there is an individual Control Plan for each piece of equipment or a manufacturing ‘cell’ ( company definition ). A ‘Technology’ consists of many similar devices. Device FMEA / Technology / Family Control Plan’ = a flow of a ‘technology’ or ‘device’ Process FMEA covers an ‘equipment set’ or ‘cost block’ Recommended by the FMEA Team FAB or Other Manufacturing Entity ‘ Receiving’ in FAB FMEAs consists of what the FAB looks at when materials arrive. Received materials, such as gasses, liquid chemicals and related materials must be addressed. Registrar interpretation Q5 1/12 (AEC-A100): “...So in effect, supplier's control plans will include wafers, gases, and chemicals...” Machine or Cell 1 ‘ Receiving’ Machine or Cell 2 Machine or Cell 3 ‘ Pack & Ship’ Internal or External Customer ‘ Receiving’ ‘ Pack & Ship’ Covers entire flow while product is under the control of the FAB including return of the product (if return is applicable)

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning One Proposed Terminology Technology Control Plan / FMEA - applies to devices, families Process Control Plan / FMEA covers an ‘ equipment set’ (cell) or individual equipment FAB or Other Manufacturing Entity Machine or Cell 1 ‘ Receiving’ Machine or Cell 2 Machine or Cell 3 ‘ Pack & Ship’

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Ship Final Pack Receiving FAB 2 Assembly FAB 1 Warehouse Customer Control Plan & FMEA Responsibility = FAB Responsibility = Materials? SQA? Responsibility = FAB Responsibility = ASSY <----------------------- Corporate Level 3 ???? -------------------------> White Space Issue Control Plan & FMEA Ctrl Plan & FMEA Ctrl Plan & FMEA Ctrl Plan & FMEA

Early on I stressed that each APQP is unique both between companies and within a company. The same is true of document changes. On the previous page I discussed some of the expected effects of a change to the process FMEA. Because of the differences in how companies structure their documentation it is only possible in a course document such as this to address the effect of changing one document on another. Another reason this is true is because every change to a process FMEA does not automatically require a change to, for example, the control plan. When the evaluation is made it may turn out that the ‘risk’ number (the RPN) may be low and thus may not require a control. In speaking of differences in company documentation, there are companies which (for example) combine their control plan and their process flow diagram into one document. This said, there is no process flow diagram per se to change. Because of the possible permutations of how a document system is set up, it is next to impossible in a course to ‘predict’ how a company will react within their documentation to a change in any given document. Another example is where a company uses the Ford Dynamic Control Plan (APQP and Control Plan manual, page 100) methodology where the control plan is combined with the process FMEA. As we proceed through this presentation, keep in mind that where we discuss the changes in one document and its effects on another you will have to look at your company’s documentation structure and determine equivalencies. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Discrete Documents

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Automotive Documentation Development Develop Process Flow Listing Enter Every ‘ Major ’ Process from Flow Listing into FMEA Form Develop FMEA(s) Element for Every Process Check for Customer Requirements. Give careful consideration to what you consider a ‘ Major ’ process. Give careful consideration to defining Control Plan stages: Prototype Pre-launch Production Use the appropriate RPN numbers and considerations of other appropriate information /data to determine Critical Characteristics. Develop the Control Plan with Critical characteristics Develop control mechanisms appropriate for Critical characteristics. Critical / Special Characteristics Process FMEA Process Control Plan Process Flow Diagram

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Base Documentation Critical Characteristics Matrix Process Flow Diagram Design FMEA Process FMEA Control Plan

A Control Plan is a written description of systems for parts and processe s It is Process Dominated Three ‘Types’ or Phases Prototype *A Design Output Used During Prototype Build Dimensional Measurements Material and Performance Tests Pre-Launch Update After Prototype and Before Production Production Comprehensive Process Controls Test and Measurement Systems Used Reaction Plan Sampling Plans SPC Requirements Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning The Control Plan

Example Control Plans included in the APQP Manual (starting on page 47): Equipment Set-Up Dominant Process Machine Dominant Process Fixture/Pallet Dominant Process Tooling Dominant Process People Operator Dominant Process Material Material or Component Dominant Process Methods Preventive Maintenance Dominant Process Environment Climate Dominant Process Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Example Control Plans

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Control Plan Data Sources Link to flow diagram & PFMEA Link to Characteristics Matrix Drawing Process Engineering PFMEA, Drawing Process Engineering Quality Engineering Process Engineering, Quality Engineering Note that in your company, you might label departments or functional areas differently, or you may assign responsibilities differently. Process Engineering in one company is called Manufacturing Engineering in another company. In addition, your company may use multi-functional input where in this example a single source is identified. Your task is to identify where, in your company, you derive the required information for each column. Process Engineering

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Ford’s Concept to Customer (CTC) Initiated in 1984. Technically obsolete.

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning QS 9000 APQP Involves: 4.1 Management Responsibility 4.2 Quality System 4.3 Contract Review 4.4 Design Control 4.5 Document and Data Control 4.9 Process Control 4.10 Receiving (Incoming) 4.11 Inspection, Measuring and Test Equipment 4.12 Inspection and Test Status 4.13 Control of Nonconforming Product 4.14 Corrective Action 4.15 Handling, Storage, Packaging and Delivery 4.16 Quality Records 4.18 Training 4.19 Servicing 4.20 Statistical Techniques

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Automotive Documentation Development Develop Process Flow Listing Enter Every ‘ Major ’ Process from Flow Listing into FMEA Form Develop FMEA (s) Element for Every Process Check for Customer Requirements. Give careful consideration to what you consider a ‘ Major ’ process. Give careful consideration to defining Control Plan stages: Prototype Pre-launch Production Use the appropriate RPN numbers and considerations of other appropriate information /data to determine Critical Characteristics. Develop the Control Plan with Critical characteristics Develop control mechanisms appropriate for Critical characteristics.

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning APQP Design & Process Controls Design Reviews Design Verification Design Validation Process Validation Design FMEA Process FMEA Prototype Validation

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product Quality Planning Responsibility Matrix AIAG APQP & Ctrl Plan Reference Guide, Page 2

Design FMEA Design Information New Equipment, Tooling and Test Equipment Product/Process Quality Flow Plan Process Flow Chart Process FMEA Control Plan Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product Quality Planning Checklists Check Lists for these line items are in the AIAG’s APQP & Control Plan reference manual contained as a group - Appendix A starting on page 63. Use them!

Ensures early planning takes place Directs resources to the customer Identifies required changes early in the process Provides quality product on time and at lowest cost Enables cross-functional inputs and outputs Addresses potential problems early in Design Manufacturing Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Benefits of APQP

KEY** Organize a Cross-Functional TEAM Define the scope Team-to-team communications Training Simultaneous (concurrent) engineering Control Plan Phases Prototype Pre-Launch Production Concern resolution Includes analytical techniques Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Progressive Fundamentals

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Training Customer Needs and Expectations Working as a Team Group process skills Development skills Requirements of APQP FMEA APQP PPAP

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Recommended Statistical Courses Basic Business Advanced Business Measurement System Analysis Statistical Process Control Design of Experiments Office, Staff, & Management Selected Staff, & Management Production Floor, Production Staff & Management, All of Quality & Engineering Production Staff & Management, All of Quality & Engineering Specific Production Staff, Quality Engineers& QA Manager & Product Engineering *Your APQP Team should attend as many classes as time will allow

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product Quality Planning Timing Chart AIAG APQP & Ctrl Plan Reference Guide, Page 5

Identify individual tasks Track resources by task Establishes dependencies between tasks Determine critical path Track specific tasks or groups of tasks Status reports Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Timing Plan Contents

Mission Scope Objectives Requirements How to measure Definitions and specifications Market analysis Feasibility Time Resources Plant space Etc. Timeline Control system Team Cost Estimate Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Project Plan Elements Consider this a ‘laundry list’ for an index. Each item does not, however, have to reside in ‘one book’. You should have (at least) an index of the project plan with the location and owner (responsibility) of each element clearly identified.

Mission - Goal, customer and approach Scope - What will and will not be included (with consideration to available technology) Objectives - Technical, profit, performance, quality, etc. Requirements - Deliverables Definition and specification - Criteria it must meet Market analysis - Expected annual production volume, length of run, start (delivery) target date, target price (Japan), key sales points, key competitors, etc. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Project Plan Definitions I

Preliminary Feasibility - Degree to which current tooling and equipment can be used Timeline - Major milestones and detail task schedule Control system - Answers questions such as: How will progress be measured? Who will receive reports? How are changes handled? What limits are there on authority, responsibility, and accountability? Team - Who, from where and who is the team leader? Beware of Turf Wars! Cost estimate - Estimate with assumptions. Often ‘all’ information is not available. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Project Plan Definitions II

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Project Plan Summary Sheet Broad Specific Project vs D&D (Design & Development)

Assembly Build Variation Analysis Benchmarking Cause & Effect Diagram Characteristics Matrix Critical Path Method Design of Experiments (DOE) Design for Manufacturability & Assembly (DFM & DFA) Design Verification Plan & Report (DVP&R - Chrysler & Ford) Dimensional (Dynamic) Control Plan (DCP) Mistake Proofing (Poka-Yoke) Process Flow Charting Quality Function Deployment (QFD) System Failure Mode & Effects Analysis (SFMEA) Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Analytical Techniques See AIAG’s APQP & Control Plan reference manual appendix B, pages 81 thru 85

Characteristics I CHARACTERISTIC : A distinguishing feature, dimension or property of a process or its output (product) on which variable or attribute data can be collected. (P39 APQP) CHARACTERISTIC, CRITICAL, CHRYSLER DEFINITION: Characteristics applicable to a component, material, assembly, or vehicle assembly operation which are designated by Chrysler Corporation Engineering as being critical to part function and having particular quality, reliability and/or durability significance. These include characteristics identified by the shield, pentagon, and diamond. (49 PPAP) CHARACTERISTIC, CRITICAL ( INVERTED DELTA ), FORD DEFINITION: Those product requirements (dimensions, performance tests) or process parameters that can affect compliance with government regulations or safe vehicle/product function, and which require specific supplier, assembly, shipping, or monitoring and included on Control Plans. (P49 PPAP) CHARACTERISTIC, CRITICAL, GM DEFINITION: See Key Product Characteristic. (P49 PPAP) CHARACTERISTIC, KEY CONTROL (KCCs): Those process parameters for which variation must be controlled around a target value to ensure that a significant characteristic is maintained at its target value. KCCs require ongoing monitoring per an approved Control Plan and should be considered as candidates for process improvement. (P49 PPAP) CHARACTERISTIC, KEY PRODUCT (KPC): Those product features that affect subsequent operations, product function, or customer satisfaction. KPCs are established by the customer engineer, quality representative, and supplier personnel from a review of the Design and Process FMEA’s and must be included in the Control Plan. Any KPCs included in customer-released engineering requirements are provided as a starting point and do not affect the supplier’s responsibility to review all aspects of the design, manufacturing process, and customer application and to determine additional KPCs. (P49 PPAP)

Characteristics II CHARACTERISTIC, PROCESS: Core team identified process variables (input variables) that have a cause and effect relationship with the identified Product Characteristic(s) which can only be measured at the time of occurrence. (6.3 #20 APQP) CHARACTERISTIC, PRODUCT: Features or properties of a part, component or assembly that are described on drawings or other primary engineering information. (6.3 #19 APQP) CHARACTERISTIC, PRODUCT, CRITICAL (D), CHRYSLER DEFINITION: A defect which is critical to part function and having particular quality, reliability, and durability significance. (QS-9000) CHARACTERISTIC, PRODUCT, MAJOR , CHRYSLER DEFINITION: A defect not critical to function, but which could materially reduce the expected performance of a product, unfavorably affect customer satisfaction, or reduce production efficiency. (QS-9000) CHARACTERISTIC, PRODUCT, MINOR , CHRYSLER DEFINITION: A defect, not classified as critical or major, which reflects a deterioration from established standards. (QS-9000) CHARACTERISTIC, PRODUCT, SAFETY/EMISSION/NOISE (S), CHRYSLER DEFINITION: A defect which will affect compliance with Chrysler Corporation and Government Vehicle Safety/Emission/Noise requirements. (QS-9000) CHARACTERISTIC, SAFETY , CHRYSLER DEFINITION “Shield <S>: Specifications of a component, material, assembly or vehicle assembly operation which require special manufacturing control to assure compliance with Chrysler Corporation and government vehicle safety requirements. (QS-9000)

Characteristics III CHARACTERISTIC , SAFETY , CHRYSLER DEFINITION: Specifications which require special manufacturing control to assure compliance with Chrysler or government vehicle safety requirements. (P50 PPAP) CHARACTERISTIC, SIGNIFICANT , CHRYSLER DEFINITION: Special characteristics selected by the supplier through knowledge of the product and process. (QS-9000) CHARACTERISTIC, SPECIAL : Product and process characteristics designated by the customer, including governmental regulatory and safety, and/or selected by the supplier through knowledge of the product and process. (P104 APQP) CHARACTERISTIC, SPECIAL, CHRYSLER DEFINITION “Diamond” <D>: Specifications of a component, material, assembly or vehicle assembly operation which are designated by Chrysler as being critical to function and having particular quality, reliability and durability significance. (QS-9000) CHARACTERISTIC, SPECIAL, CHRYSLER DEFINITION “Diamond” <D>: Specific critical characteristics that are process driven (controlled) and therefore require SPC to measure process stability, capability, and control for the life of the part. (Appendix C QS-9000) & (Appendix C APQP) CHARACTERISTIC, SPECIAL, CHRYSLER DEFINITION “Pentagon” <P>: Limited to highlighting Critical characteristics on (Production) part drawings, tools and fixture, and tooling aid procedures where ongoing process control is not automatically mandated. (Appendix C QS-9000) & (Appendix C APQP) CHARACTERISTIC, SPECIAL, CHRYSLER DEFINITION “Shield” <S>: Engineering designated specifications or product requirements applicable to component material, assembly operation(s) which require special manufacturing control to assure compliance with governmental vehicle safety, emissions, noise, or theft prevention requirements. (Appendix C QS-9000) & (Appendix C APQP)

Characteristics IV CHARACTERISTIC, SPECIAL, FORD DEFINITION “Critical Characteristic” <Inverted Delta>: Those product requirements (Dimensions, Specifications, Tests) or process parameters which can affect compliance with government regulations or safe Vehicle/Product Function and which require specific producer, assembly, shipping or monitoring actions and inclusion on the Control Plan. (Appendix C QS-9000) & (Appendix C APQP) CHARACTERISTIC, SPECIAL, FORD DEFINITION “Significant Characteristic - SC” <None>: Those product, process, and test requirements that are important to customer satisfaction and for which quality planning actions shall be included in the Control Plan. (Appendix C QS-9000) CHARACTERISTIC, SPECIAL, FORD DEFINITION “Significant/Characteristic - S/C” <None>: Characteristics that are important to the customer and that must be included on the Control Plan. (Appendix C APQP) CHARACTERISTIC, SPECIAL, GM DEFINITION “Fit/Function” <F/F>: Product characteristic for which reasonably anticipated variation is likely to significantly affect customer satisfaction with a product (other than S/C) such as its fits, function, mounting or appearance, or the ability to process or build the product. (Appendix C QS-9000) & (Appendix C APQP) CHARACTERISTIC, SPECIAL, GM DEFINITION “Safety/Compliance” <S/C>: Product characteristic for which reasonably anticipated variation could significantly affect customer the product’s safety or its compliance with government regulations (such as: flammability, occupant protection, steering control, braking, etc. . .), emissions, noise, radio frequency interference, etc. . . (Appendix C QS-9000) CHARACTERISTIC, SPECIAL, GM DEFINITION “Safety/Compliance” <S>: Product characteristic for which reasonably anticipated variation could significantly affect customer the product’s safety or its compliance with government regulations (such as: flammability, occupant protection, steering control, braking, etc. . .), emissions, noise, radio frequency interference, etc. . . (Appendix C APQP)

Characteristics V CHARACTERISTIC, SPECIAL , GM DEFINITION “Standard” <None>: Product characteristic for which reasonably anticipated variation is unlikely to significantly affect a product’s safety, compliance with governmental regulations, fit/function. (Appendix C QS-9000) & (Appendix C APQP) CHARACTERISTIC, SPECIAL , PROCESS ( e.g., CRITICAL, KEY, MAJOR, SIGNIFICANT ): A process characteristic for which variation must be controlled to some target value to ensure that variation in a special product characteristic is maintained to its target value during manufacturing and assembly. (P57 FMEA) CHARACTERISTIC, SPECIAL , PRODUCT: Core team compilation of important product characteristics from all sources. All Special Characteristics must be listed on the Control Plan. (6.3 #19 APQP) CHARACTERISTIC, SPECIAL , PRODUCT ( e.g., CRITICAL, KEY, MAJOR, SIGNIFICANT ): A product characteristic for which reasonably anticipated variation could significantly affect a product’s safety or compliance with governmental standards or regulations, or is likely to significantly affect customer satisfaction with a product. (P55 FMEA) CHARACTERISTIC, SPECIAL , TOOLING, CHRYSLER DEFINITION “Pentagon” <P>: Critical tooling symbol used to identify special characteristics of fixtures, gages, developmental parts, and initial product parts. (QS-9000) CONTROL ITEM PART, FORD DEFINITION: Product drawings/specifications containing Critical Characteristics. Ford Design and Quality Engineering approval is required for changes to Control Item FMEA’s and Control Plans. (QS-9000)

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Phase 2 Outputs Outputs by Design Responsible Activity Outputs by Advanced Product Quality Planning Team

Design FMEA DFM and DFA Design for Manufacturability Design for Assembly Design Verification Design Reviews Prototype Build - Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Outputs by Design Responsible Activity

Updated special characteristics list Prototype parts build Make - Buy decisions Parts inspection Assembly of prototype(s) Preferably manufacturing, not model shop Inspection layout Prototype validation testing Redesign as required and design review Update DFMEA (and System Level FMEA if appropriate) Feasibility report Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Additional Outputs by Design Responsible Activity

Disciplined analytical tool Assess probability of failure Effect of failure Must be continually updated Causes changes and/or additions to previously selected special product and/or process characteristics If you do not have design control, you MUST (should) have customer DFMEA Check list (AIAG APQP Manual Appendix A-1) Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning DFMEA

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning DF M and DF A Design, concept, function and sensitivity (tolerancing) to manufacturing variation Manufacturing and/or assembly process Dimensional tolerances Performance requirements Number of components (complexity) Process adjustments Material handling

Inspection methods Testing methods Ensure that all design outputs meet design input requirements Alternate calculations CAD/math data Review design stage documents before release Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Design Verification

Design/functional requirement(s) and considerations Formal reliability and confidence goals Component/subsystem/system duty cycles Computer simulation and bench test results DFMEA(s) Review of the DFM and DFA Design of experiments (DOE) and assembly build variation results Test failures Design verification progress Max/Min builds Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Design Review s - Evaluations

Track verification progress using a design verification plan and report (DVP&R - Ford & Chrysler) Product/process validation of components Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Design Review Tracking

Aids in the manufacturing of products according to customer requirements Provide structured approaches Contain a written summary of the system used in minimizing process and product variation Forms provided in the AIAG handbook are examples of how to document Alternate formats can be used if they contain necessary information Must be maintained and used throughout the product life cycle Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Control Plan Methodology

Initial: To document and communicate initial process control Next: Guidance in controlling processes and to ensure product quality Last: A living document reflecting current methods of control and measurement systems used Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Control Plan Use

Ensure Control Plan is aligned to, and correlates with, DFMEA, Process Flow, PFMEA Control Methods appropriate to variation type(s) Incorporates Lessons Learned, Statistical Data Use A-8 Control Plan checklist in APQP manual to evaluate Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Control Plan

A description of the dimensional measurements Material tests Functional tests that will occur during prototype build Depending upon product complexity, several prototype builds may be necessary and may require updates to the control plan Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Prototype Build Control Plan

Make -buy decisions Part inspections Assemble prototypes Perform layout inspection Validation testing (Who will do testing?) Redesign as required Update DFMEA and SFMEA if required Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Prototype Build

Review for special and/or critical characteristics Review controlling drawings when engineering drawings are nonexistent Review drawings for: Dimensions for form, fit, function, durability, government S&R Control or datum surfaces/locators for function gages and equipment Feasibility/compatibility with industry standards Compatibility of math data with two-way communications ( Written waivers acceptable ) Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Customer or Supplier Engineering Drawings (including math data)

Review and understand controlling specifications Identify functional, durability and appearance requirements Should define: Sample size Frequency Acceptance criteria Otherwise, determined by supplier and included in control plan Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Customer or Supplier Engineering Specifications

Review Material Specifications for Special Characteristics Physical properties Performance Environmental Handling Storage Include in Control Plan Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Material Specifications

Change control requirement applies Ensure proper communication QS 9000 Element 4.5 ‘Document and Data Control’ applies (requires a Change Control system) Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Drawing and Specifications Changes

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com APQP Team Outputs New equipment, tooling and facilities requirements Special product and process characteristics Gage and testing equipment requirements Team feasibility commitment and management support Subcontractor build Supplier build

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com New Equipment, Tooling and Facilities Requirements Preliminary identification of new equipment, tooling and facilities Address these items on the timing chart Address capability requirements Establish delivery times Complete check list in AIAG APQP & Control Plan reference manual Appendix A-3

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Special Product and Process Characteristics List Upgrade preliminary list started in Phase 1 from information gathered through review and development of design features Additional sources DFMEA SFMEA if applicable PFMEA Previous history Must be on control plans for prototype, pre-launch and production Listing should be a team consensus These may overlap

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Gage and Testing Equipment Requirements Preliminary identification of inspection, test and measurement equipment Requirements on timing chart Complete in time to conduct measurement systems analysis Equipment builder Pilot build Production trial run

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Team Feasibility, Commitment and Management Support Team feasibility commitment Complete program review check list, including: Design feasibility Can be manufactured, assembled, tested and packaged Can be delivered in the right quantities on schedule at acceptable cost Review design information check list in AIAG APQP Reference manual Appendix A-2 as part of feasibility inputs Open issues that require resolution with assigned responsibility and timing. Management Support Report project status to management Recommend continue or drop project depending on feasibility Cover open issues and concerns Management support as required

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Subcontractor Pilot Build Supplier participated, if appropriate Sample quantity required Check that it is according to: Work instructions Control plan Where to be produced

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Supplier Pilot Sample Build Parts availability Tooling and equipment availability Measurement equipment availability

Packaging Standards Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Phase 3 Outputs

DFMCA DFM/DFA DV Design Reviews Prototype Build Engineering Drawings Engineering Specifications Material Specifications Drawing and Specification Changes Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Typical Design Responsibility Outputs

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Process Design and Development Outputs Packaging standards Product and process quality system review Process flow chart Floor plan layout Characteristics matrix PFMEA Pre-launch control plan Process instructions Measurement systems analysis plan Preliminary process capability study plan (Typically 100 Parts) Management support Additional Outputs Update tooling, equipment and facilities list Update process flow chart Update PFMEA Quote in-house gages, tooling and equipment Order gages, tooling and equipment Delivery of gages in time for MSA plan Delivery of equipment Must consider approval at equipment subcontractor, in-house installation, debugging and process potential studies (runoff) Subcontractor pilot build Supplier pilot build Salable units?

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Packaging Standards From customer Developed during prototype or pre-launch runs

Team must review existing quality systems manual to ensure that changes resulting from APQP (if any) are reflected Must comply with QS 9000 Changes must be reflected in control plan Reference AIAG APQP Reference manual Appendix A-4 check list Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Product and Process Quality System Review

Update process flow chart (Example in AIAG APQP Reference manual Appendix A-6) Describes current or proposed process flow Used to analyze sources of variation Helps analyze total process Needed for process FMEA, characteristics matrix and control plan Reference AIAG APQP Reference manual Appendix A-6 check list Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Process Flow Chart

Determine acceptability of inspection and test points Control chart location(s) Visual aides Interim repair stations (rework) Nonconforming material storage Keyed to material flow and control plan Reference AIAG APQP Reference manual Appendix A-5 Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Floor Plan Layout

Displays relationship between: Process parameter Manufacturing stations Reference AIAG APQP Reference manual Appendix B, page 82 Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Characteristics Matrix

To the extent possible, potential failure modes have been considered and addressed May be started after design FMEA in Phase 2 Needs to be updated regularly Must be done prior to committing new tools and equipment Living document Typically started too late! Reference AIAG APQP Reference manual Appendix A-7 Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Process FMEA

Description of dimensional measurements, materials and functional tests Adds additional product and/or process controls Purpose is to contain potential nonconformities utilizing: More frequent inspections and/or tests More in-process and final inspection and/or check points Statistical evaluations Increased audits Reference AIAG APQP Reference manual Appendix A-8 check list Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Pre-launch Control Plan

Updated equipment, tools and facility lists Updated process flow chart, PFMEA and control plan Quotes for in-house tooling, equipment and gages Selection of potential new subcontractors Quote and delivery of gages in time for MSA plan Equipment build and runoffs Generation of a subcontractor pilot build Generation of a supplier pilot build Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Additional Phase 3 Outputs

Information from PFMEA and other sources Address on timing chart Address capability requirements Reference AIAG APQP Reference manual Appendix A-3 check list Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Updated Tool, Equipment and Facilities Lists

Delivery timing for pilot build or production trial run Include capability requirements Include trial run/runoff/prove-out requirements Gage delivery for MSA plan and runoff Reference AIAG APQP Reference manual Appendix A-3 Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Quoting In-House Tooling, Equipment and Gages

Responsible for planning, tracking and follow-up for subcontracted work Provide technical resources for tool and gage design, fabrication and full dimensional inspection Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Selecting Potential New Subcontractors

Supplier participation, if appropriate Build sample quantity required Machine trial runs Pilot run(s) In accordance with appropriate work instructions In accordance with control plan Production tooling and equipment, if possible Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Subcontractor Pilot Sample Build

Provide for customer participation, if specified have process instructions in place Have control plan in place Provide required quantity Complete MSA Generate required documentation as planned Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Supplier Pilot Build

Include in control plan Manufacturing location’s quality system manual should be reviewed Procedures and control plans to be updated to reflect changes Last chance to eliminate problems before ramp-up Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Project Review III

Production trial run Measurement system evaluation (complete) Preliminary process capability study Production part approval Production validation testing Packaging evaluation Production control plan Quality planning sign-off and management support Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Phase 4 Outputs

Work instructions for operating personnel Sources: FMEAs Control plans Engineering drawings and specifications Material specifications Visual standards Industry standards Process flow chart Floor plan layout Characteristic matrix Packaging standards Process parameters Producer expertise Handling requirements Operators of process Accessible operators Include set-up parameters Reference QS 9000 Element 4.9 ‘Process Control’ Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Process Instructions

Complete studies as defined in the MSA plan Minimum are those identified in the control plan Subjected to evaluation prior to or during production trial Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Measurement Systems Analysis (MSA)

Measurement uncertainty determined Gage R&R, Bias, Stability, and Linearity Gage R & R acceptance guidelines < 10% acceptable 10-30% may be acceptable, evaluate total variation >30% unacceptable, measuring system needs improvement Verify study performed correctly Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning MSA Studies

Measurement Systems Analysis Plan Ensures Gage:  Linearity  Accuracy  Repeatability  Reproducibility  Correlation for duplicate gages Gages may be needed prior to gage sign-off at subcontractor plant or any in-house pilot runs Measurement Instrument Environment Material Inspector Methods Sample Preparation Sample Collection Parallax Reproducibility Training Practice Ergonomics Test Method Workmanship Samples Standards Discrimination Repeatability Bias Calibration Linearity Vibration Lighting Temperature Humidity These are some of the variables in a measurement system. What others can you think of?

Precise Imprecise Accurate Inaccurate Bias You can correct for Bias You can NOT correct for Imprecision Measurement Bias & Repeatability

Must include characteristics identified in control plan Few characteristics for simple component Many characteristics for complex product with many parts Reference AIAG Fundamental SPC Reference Manual Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Preliminary Process Capability Study Plan

Packaging must conform to specifications developed by customer or supplier Assess protection of product Customer specified packaging must be evaluated by team Pilot or production trial run parts usually used in evaluation Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Packaging Evaluation

For individual products Customer packaging Generic standards where appropriate Must ensure delivery quality Compatible with all material handling equipment used Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Packaging Specifications

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning PPAP The End Product of APQP! APQP Launch Binders PPAP Submission Sub-Set

PPAP Production parts are manufactured at the production site using production tooling, gaging, equipment, operators, etc Parts from production run are analyzed. Test results and records from APQP are submitted with Part Submission Warrant. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning P roduction P art A pproval P rocess

For the supplier to demonstrate: All design records and specification. Requirements are properly understood. The process has the capability to produce product that meets requirements. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Purpose of PPAP

Production Part Approval Process Parts produced at production site using: Production tooling Production gages Process Operators Environment Process settings Feeds Speeds Cycle times Pressures Temperatures Intent is to validate (prove) that products made using production equipment meet engineering requirements If submission level is not known, contact customer Default level is 3 Customer approval is required prior to quantity production Reference AIAG Production Part Approval Process reference manual Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Production Part Approval Process ( PPAP )

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning PPAP Review Checklist Checklist to assist with evaluation of PPAP package Action plan created with use of checklist

Production parts - generally 300 ‘pieces’ Service subcontractors - fulfill requirements Bulk material Includes internal and external sources for information Submission required prior to first production shipment PPAP Manual Section I.3 “ Customer Notification and Submission Requirements ” (starting on page 11) for guidance Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning PPAP Scope

AIAG PPAP Manual Defines When PPAP Submission is Required New part Correction to discrepancy in previous submission Design or process change Change in source of subcontracted materials or services Transfer or rearrangement of tooling & equipment Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Application Something Changed

Approver evaluates PPAP package. Level 5 at supplier site Approver determine part submission status. Notify supplier and manufacturing of status. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Methodology Buyer enters PPAP submission date on purchase order. Approver determines submission level. Default level 3 Default level 4 for raw material Supplier submits PPAP PPAPALL.xls electronic submission (Delphi)

DFMEA Control Plan Early Production Containment Plan (Pre-Launch Control Plan) Process capability studies Gage Measurement System Analysis Lab Accreditation & scope Restricted & Reportable Materials form Interim Worksheet, if required Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Supplier Data Received Warrant Appearance Approval Report (AAR), as required Sample Parts Print/Design Record Engineering Change Documents Check fixtures/aids Process Flow Diagram PFMEA

Linkage of Product Characteristics from DFMEA to Operational Steps. Operation numbers consistent with PFMEA , Control Plan , Operator Instructions. Ensure identification of inspection and rework. Use A-6 Process Flow Chart checklist in APQP manual to evaluate. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Flow Chart

Assess Feasibility, Risk, Design Intent Issues Confirm Manufacturing Process Capability Considered Focus on Critical Characteristics Lessons Learned Incorporated Use A-1 Design FMEA Checklist in APQP Manual to Evaluate Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning DFMEA

Linkage with DFMEA, Process Flow, Control Plan, Operator Instructions, etc Degree to which high RPN’s are addressed with preventive strategies Action Plans assigned, implemented, effectiveness assessed and RPN recalculated Use A-7 Process FMEA checklist in APQP manual Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning PFMEA RPN = 504

Early Production Containment Requirements 1. Additional controls included for proper duration or quantity. 2. PFMEA and statistical data used to determine what additional controls necessary. Short Term Capability Long Term Capability on similar process Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Pre-Launch Control Plan

Update pre-launch control plan (living document) Add: Sampling plans Control method SPC, inspection, attribute data and mistake-proofing Reaction plan Nonconformances clearly identified, quarantined and disposition made Requires customer approval unless otherwise specified Reference AIAG APQP Reference manual Appendix A-8, B and G Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Production Control Plan

Engineering tests validate products manufactured with: Production tools Production processes Production operators Performed under end-use operating conditions Multiple validations for multiple intended uses Reference QS 9000 Element 4.4.8 Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Production Validation Testing

Production tooling, equipment, environment, facilities and cycle time Process instructions and control plans Minimum quantity set by customer (Can be increased by team) Generally 300 parts Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Production Trial Run

Preliminary process capability studies MSA (if not completed earlier) Final feasibility Process review Production validation testing PPAP Packaging evaluation First time capability Quality planning sign-off Design changes (if required) Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Production Trial Run Product Used For:

In 1991, the ASQC/AIAG Task Force published the "Fundamental Statistical Process Control" reference manual, which shows the calculations for Cpk as well as Ppk. These should be used to eliminate confusion about calculating Cpk. So which value is best to report, Cpk or Ppk? Although they show similar information, they have slightly different uses. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Ppk vs. Cpk Estimated sigma and the related capability indices (Cp, Cpk, and Cr) are used to measure the potential capability of a system to meet customer needs. Use it when you want to analyze a system's aptitude to perform. Actual or calculated sigma (sigma of the individuals) and the related indices (Pp, Ppk, and Pr) are used to measure the performance of a system to meet customer needs. Use it when you want to measure a system's actual process performance.

Characteristics identified in the control plan Usually 100 pieces minimum May be 30 if run is less Ppk ≥ 1.67 is acceptable unless otherwise specified Ppk ≤ 1.67 requires action plan unless otherwise specified Reference AIAG Fundamental SPC Reference Manual 1.0 at spec limit +-3 sigma = 1.67 Allows ‘flop’ within spec limit Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Preliminary Process Capability Studies

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Process Analysis Animation Courtesy of The Red Road http://www.sci.fi/~leo/

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Histogram Animation Courtesy of The Red Road http://www.sci.fi/~leo/

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Elsmar.com Process Capability Animation Courtesy of The Red Road http://www.sci.fi/~leo/

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Part Submission Status Possibilities Full Production Approval Interim Approval Authorize shipment to Delphi without Full Production Approval Corrective Action Plan is required. Rejected Corrected submission required before production quantities may be shipped.

B Parts from production tooling and require rework to meet specs. C Parts not from production tooling, parts meet specs. D Parts do not meet specs. E Parts do not meet specs and vehicles with class E parts require retrofit to make them saleable. Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Interim Part Classes A Parts from production tooling and meet specs, not all PPAP requirements have been met.

Process instructions in place and followed Flow charts in place and followed GR&R plans exist and are followed Publish final feasibility report Obtain formal sigh-off Schedule and conduct management review Obtain management commitment to assist in open issues Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Review and Sign-Off

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning APQP Phase 5: Feedback, Assessment and Corrective Action The results of continuing production are evaluated for common or special causes of variation during this phase to ensure that the products satisfy customer satisfaction requirements The effectiveness of the quality process should be evaluated during this process step Includes continual improvement efforts Includes delivery and service performance

Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Continuing Production Continuing Production Determining Ongoing Capability Continuing Production Develop & Implement Corrective Action Plan Measure Delivery & Service Measure Customer Satisfaction Cpk > or = 1.33 Attend Customer QOS Meeting As Required Continuous Improvement Plan & Feedback Develop QOS Measurement Develop Delivery & Service Measurement Plan Ford’s Interpretation

Reduced variation Customer satisfaction Delivery and service Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Phase 5 Outputs

Identify process variation take corrective action to reduce variation Develop proposal for customer review Gain customer decision to implement, negotiate or change design Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Reducing Variation

Product or service must perform in customer’s environment Supplier must participate Supplier and customer must be partners Reference QS 9000 Element 4.1.6 Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Customer Satisfaction

Warranty Labour claims Concerns reports Nonconforming material reports Corrective actions On time delivery Tech calls Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Customer Satisfaction Metrics Customer rating Returns PPM Response time On-site representative Market share Cost control (total cost)

Continues the supplier - customer partnership in problem solving and continuous improvement Replacement parts and services are important Leads to possible price reduction from: Inventory cost reduction Process cost reduction Cost of quality reduction Reference QS 9000 Element 4.15 Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Delivery and Service

AIAG PPAP Manual Defines Requirements APQP Product and Process Validation Supplier submits PPAP to proper level PPAP package evaluated and status determined Supplier and customer manufacturing site notified of PPAP approval status Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning Summary

A-1 Design FMEA Check List A-2 Design Information Checklist A-3 New Equipment, Tooling and Test Equipment Checklist A-4 Product / Process Quality Checklist A-5 Floor Plan Check List A-6 Process Flow Chart Checklist A-7 Process FMEA Checklist A-8 Control Plan Checklist Slide The Cove! -- Elsmar.com © 2003 The Elsmar Cove - Rev U Rendered Sunday, October 30, 2011 Advanced Product Quality Planning APQP Manual Appendix A - Check Lists

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