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7/25/2019 2007 APQP Program Mgmt Classroom
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Supplier APQP Overview
The Global Leader in
Automotive Safety Systems
2005TRWA
utomotive
TRWs High Performance Brake Calier!
And the life it helps protect.2005TRWA
utomotive
TRWs "lectricall# Po$ere% &teering an% "lectronic
&ta'ilit# Control stem $ork together to hel kee
vehicles on the roa%! And these lives safe!
TRWs Air'ag "lectronic Control (nit!
And the life it helps protect.
2005TRWAutomotive
TRWs &i%e )mact Rollover Protection stem!
And the lives it helps protect.
2005TRWAutomotive
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What is the goal of this module?What do we want toachieve?
To provide an understanding of what the SupplierDevelopment Teams responsibilities are, in terms
of the APQP process.
To provide an understanding of the roles andresponsibilities between the cross function
departments engineering, purchasing, program
management, operations!.
To provide an understanding of the importance of allcross functions working together to achieve a
flawless launch.
Supplier APQP Overview
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"usiness Polic# $anual "P$!
Supports goal of onecompan#, one process,
one standard.
%epositor# for both
automotive and product
line processes.
D& Suppl# $anagement
contains supplier APQP
documents.
Click on the picture to find out.
What is the BPM?
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"usiness Polic# $anual "P$!
http://oeforums.shrluk.trw.com/bem/dispatch
.exe/bpm_docs
Click picture for links
Where can I find the BPM?
A link can be foundon the TRWAutomotive
homepage or anyother product line
website.
Or you cn type t!e "R# into your $ro%&er''re&& %in'o%(
http://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docshttp://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docshttp://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docshttp://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docs7/25/2019 2007 APQP Program Mgmt Classroom
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'DP($
I& it t!e *lo$l +evelopment, -ro'uct Intro'uctionn/ement
What is GDPIM?
Is it the Global DesignProcess for Integration &
Management?
Click picture tostart
No, Try Again
ClickHere
ClickHere
or
Congratulations!
That is correct.
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Checklists, phasedefinitions,priority
assessments.
Used forcustomer
specific product
launches.
Pre-definedstages with exitreviews assure
containment ofissues.
'DP($ Consists of ProgramManager, Engineering,
Operations, Qualityand Purchasing.
Cross
FunctionalTeam
PhasedApproach
Core EngrgModule
ApplicationEngrgModule
DefinedTools &
Techniques
GDPIM
Applies to development
of new products.
CLICK HERECLICK HERE
CLICK HERE CLICK HERE
CLICK HERE
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'DP($
'DP($ is found in
the "usinessPolic# $anual,
Section A.
Where can I find the GDPIM procedure and relateddocuments?
Click on the compass tofind out.
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'SQ$
The 'SQ$ is T%)s 'lobal SupplierQualit# $anual.
This manual documents T%)se*pectations and re+uirements from
its direct material suppl# base.
The scope of the manual includes allsuppliers who directl# affect the
+ualit# of production materials.
(t does not include& $%O (nternal suppliers
What is the GSQM?
Click on picture for answer
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'SQ$The 'SQ$ is divided into sections&
Supplier QualificationRequirements
APQP and PPAPprocesses
Serial Production
requirements
Continuous Improvement
Links to allreferenced formsand procedures.
Definition of theapplication of thedocument.
Responsibilities andformats.
Governmental and
Environmentalregulationcompliance. Introduction Documents
Table
Automotive
Requirements
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'SQ$W!ere i& t!e * #octe'(
Click on picture for locations
Internally it can be found athttp://vinet.livmi.trw.com/on
the Intranet, or
It can also be found at TRWAutomotive(http://www.TRWAuto.com)
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)hat is APQP-
5Alterntive -ro'uct uliiction -roce&&7 %!ic! i& &y&temticpproc!8 %!ic! re&ult& in component& pprove' --A-8 %!en t!e'r%in/ i& rele&e' lte.
5Acci'entl -ro'uction o ulity -rt&7 &upplier p!ilo&op!iclpproc! re&ultin/ in unplnne' conormnce to t!e 'r%in/.
5A'vnce' -ro'uct ulity -lnnin/7 &y&temtic pproc!8 %!ic!re&ult& in pln or controllin/ mnucturin/ proce&& n'or pro'uct inor'er to meet t!e cu&tomer& re:uirement&.
Is it???
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OOPS! A good guess,but not the correct
answer. Click heretotry again.
)hat is APQP-
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)hat is APQP-
(t can also be usedfor drawingchanges, supplierprocess changes
and tool moves.
Click on each sign if more information
Starts in DesignValidation phaseof GDPIM.
Finishes with
full approval,or release ofPPAP.
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/e# 0lements of APQP
A met!o' o i'entiyin/ t!o&e componenteture& t!t ect it8 orm8 unction8&&em$ly n' mnuctur$ility.
pecial
Characteristics
Manufacturing
Feasibility
Failure modes
effects
analysis
Control plan
T!e $ility to mnucture t!e component8in &uicient :untitie& n' %it! ccept$le
:ulity8 to t!e cu&tomer;& re:uirement&.
A study of what can go wrong in amanufacturing process and what controlswill be use to reduce the risks.
The listing of controls used, based onthe FMEA, detailing characteristics,methods, frequencies, and reaction to
process non-conformances.
Click on term to see definition.
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1ow that #ou are prepared, lets start our overview2
Supplier APQP Overview
)hat is the primar# form of communication in and out of T%)-
clic3 on what #ou thin3 is the correct answer!
PROPOSAL
WRONG. TRY AGAIN!The drawing is correct. It represents
the ocal point or all reiews, actiitiesand actions.
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4ets ta3e #ou through a scenario as an e*ample22
Supplier APQP Overview
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APQP Scenario
I you %ere t
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APQP Scenario
?e@t8 you %oul' nee' mp n''etermine %!ic! route you %oul'$e t
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APQP Scenario
I 'rivin/8 you %ill nee' to/et t!e cr re'y or t!e trip.
Are ne% tire& nee'e'
W!en 'i' you l&t /et noil c!n/e
TuneDup
+on;t or/et t!e !ou&eE top t!e mil 'elivery .
T!e ne%&pper.
Click on picture
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APQP ScenarioHow does this relate to a TRW launch?
(click on arrow for relationship)
Length of Vacation Launch Window
Road map Product drawing
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APQP Scenario
Places we must see
Special (designated)Characteristics
(Click on arrows)
Process FlowDiagramTravel itinerary
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APQP Scenario
Thisand
not thisDesign FMEA
Not this,but this
Process FMEA
(click on arrows)
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APQP Scenario(click on arrow)
Control Plan
Packing, shopping,things to do lists,
agendas,itineraries, etc.
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Leads theteam;
responsiblefor quality oflaunch.
Supplier 5omponent APQP Process
THE KEY PLAYERS ARE:
Program
Manager
Engineer
Operations
CommodityManager
Supplier
SupplierDevelopment
Engineer
LaunchCoordinator,Logistics andManufacturingEngineeringparticipate.
Works with
supplier tovalidate
componentsmanufacturingprocess.
Responsible forproduct designand functionality.May include
both Core andApplications.
Responsiblefor supplierselection &commercial
relationship.
Responsible formanufacturingthe component tomeet the
drawingsrequirements.
(Click on picture for explanation)
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Supplier 5omponent APQP Process
The first step is the Component Priority Assessment (CPA)(click on picture)
What is it?
A process to identify which
component(s) and/orsupplier(s), involved in anygiven launch, require a focusedeffort from Kick-off toProduction by the SDE and/or a
cross-functional team.
Lead by:NPISupported by:Program ManagementEngineeringCommodity ManagementSDE/SQA
Operations
Who Attends?
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click on picture)
+eine& %!ic! proce&&e&8 in t!e +F tool$o@8 %!ic!re employe' $&e' on element &core&.
BENEFITS I'entiie& erly in pro/rm %!ic! component&8
e&pecilly in comple@ &&em$lie&8 re li
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click on picture)
T%o &ection& one or Frly ourcin/ n' t!e ot!er orpro'uction.
corin/ i& 'ierent or Frly ourcin/.
Totl &core& re utomticlly clculte'8 %it! &ttu& or
cte/ory &!o%n.
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click on picture)
FAR#> O"RCI?* AFF?T Fi/!t cte/orie&.
=ocu& i& on &upplier8 &c!e'ule n' component comple@ity.
Cn $e u&e' or core or ppliction proect&.
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click on picture)
#A"?CB corin/8 $&e' on 'eine' criteri8 my $e )08 10 or 1.
Overlp o t%o cte/orie&.
Fc! prt cte/oriHe' & A8 G or C8 %!ic! 'eine& +F&
'e/ree o involvement.
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click here)
6.
.*
x
1.Select FirstPart Number
2.EvaluateAgainst EachRiskCategory
3.Form Automatically
Calculates Total Score
4.Select NextPart Number
THE PROCESS:
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click on picture) 5AT0'O%7 A 5O$PO101TS&
Bi/!e&t c!nce o lunc! i&&ue&.
Re:uire& totl &core o 200 or more.
!oul' $e e% in num$er $out 3D)J. T!e&e aret!e criticl e%.
Ge&t repre&ent& ne% tec!nolo/ie&8proce&&e& n'or &upplier&.
Re:uire& &&i/nment o upplierC!mpion $&e' on &&e&&mentcte/ory &corin/.
+oe& not inclu'e c!ronic i&&ue
&upplier&.
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click on picture)
5AT0'O%7 " 5O$PO101TS&
o'erte c!nce o lunc!
i&&ue&. Totl &core i& rom 100 to 199.
!oul' $e e% in num$er $out10D1)J.
Ge&t repre&ent& c!ronic i&&ue&8tec!nolo/y evolution n'or poor:ulity perormnce.
"tiliHe& &electe' tool& $&e' on
&corin/.
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA)(click on picture)
5AT0'O%7 5 5O$PO101TS
#o% c!nce o lunc! i&&ue&.
Totl &core o le&& t!n 100. !oul' $e t!e mority o t!e
component&.
Ge&t repre&ent& current
tec!nolo/ie&8 proce&&e& n'ccept$le :ulity perormnce.
A-- con'ucte' $y &upplier--A- only &u$mi&&ion
re:uirement.
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Supplier 5omponent APQP Process
Component Priority Assessment (CPA).
(click on picture)
DOCUMENTATION:
Work Instruction:
D_020_3_03Form
D_020_4_08 Assessment
Element Definitions Utilization Matrices
Location
Business Policy Manual
Section D
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Supplier 5omponent APQP Process
5 PHASES
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Supplier 5omponent APQP Process& 8 Phases
PHASE 1: Supplier Kick-off and Planning
Applie& to ll Cte/ory A component&.
Applie& to Cte/ory G n' C component&$&e' on t!e +F;& c!oice.
Goals (click on picture to left) Communicte pro/rmcomponent
unctionlity.
F&t$li&! proect time line8 /ol& n'e@pecttion&.
I'entiy i&&ue& %it! t!e &upplier;&$ility to mnucture t!e component.
Scope (click on picture at right)
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Supplier 5omponent APQP Process& 8 Phases
PHASE 1: Supplier Kick-off and Planning
Fn'& %it! completion o t!e Kic
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Supplier 5omponent APQP Process& 8 Phases
PHASE 1: Supplier Kick-off and Planning INPUTS
Program Mgr
SDE
EngineerStarts long lead tooling early enough tomeet program timing; Process design ismore robust.
DELIVERABLE
EngineerIdentifies critical features andfunctionalities that can be incorporated intoprocess and tooling design.
IMPACTRESPONSIBILITY
Buyer
Communicates program needs anddeliverables to all participants.
Defines expectations andvalidation requirements.
Establishes capacity requirements
the suppliers process must meet.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 1: Supplier Kick-off and Planning OUTPUTS
Supplier
Supplier
SDEDocuments review of drawing, technicaland commercial issues.
DELIVERABLE
SupplierDisplays suppliers plan for meetingprogram deliverables.
IMPACTRESPONSIBILITY
Identifies all suppliers, regardless of sub-
tier level, who impact the final part.
Defines all special characteristics andpoint in process they are manufactured.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools-APQP Workbook
In the Business Policy Manual andthe GSQM.
D_020_4_003.xls
A collection of APQP forms thatwould be used regardless ofpriority ranking.
APQP Progress Report,SupplyChain Map,Key Metrics Report,Product Characteristics Matrixand
Open Issues Action Plan.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools-APQP Progress Report
Provides supplier timing andprogress on key APQP deliverables.
Periodic submission to SDE for allpriority A and B components.
Further detail, i.e., tool build timing,captured in supplier timeline.
Status of completion one of the KeyMetrics.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Supply Chain Map
Used to define deep and/or complex supply chains.
Identifies suppliers that affects quality of special characteristics.
Further defined in Product Characteristics Matrix (PCM).
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Supplier 5omponent APQP Process& 8 Phases
PHASE 1: Supplier Development Tools Key Metrics Report
Focuses APQP on resultsrather than events.
Twelve key metrics allow
multiple updates todemonstrate current status andprogress over time.
Four primary indicators providea quick picture of the process.
Automatically generates agraph.
Operational definitionsprovided.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 1: Supplier Development Tools PCM
Ties DFMEA,Component PFMEA,Control Plan and Supply
Chain Map together.
Forms basis of SafeLaunch Plan (SLP) andis hand-off from SDE toOperations/SQA.
Engineeringparticipation essential tosuccess.
Initiated at Design
Review.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Open Issues Action Plan
Combines all separatedaction plans into a singledocument.
Started at Kick-offmeeting.
Supplier is owner of thedocument.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Design Review
Found in Business PolicyManual and GSQM.
Document No: D_020_4_04
Cross functional participationcritical for event success.
Includes detailed review of everydimension, note andspecification on.
Unresolved issues identified atthe Design Review often createlaunch and serial productionissues.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Launch Readiness Audit
Found in Business Policy Manualand GSQM.
Document No: D_020_4_09
Scored audit grades suppliersstate of preparation for start-of-production.
Is one of the Key Metrics.
Requires a score of 90%, or more,
to show readiness for launch.
Can be used at different pointsthroughout APQP to measureprogress.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 2: Equipment and Tool Design
Applie& to ll Cte/ory A component&.
Applie& to Cte/ory G n' C component&$&e' on t!e +F;& c!oice.
Goals (click on picture to left)
Re&olve i&&ue& i'entiie' in A-- 1.
Approve t!e &upplier;& 'e&i/n ortoolin/8 proce&& n'or /u/in/.
Scope (click on picture at right)
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Supplier 5omponent APQP Process& 8 Phases
PHASE 2: Equipment and Tool Design
Fn'& %it! t!e &upplier;& completion ot!eir toolin/8 e:uipment n'or /u/in/'e&i/n.
Ge/in& %it! completion o Kic
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Supplier 5omponent APQP Process& 8 Phases
PHASE 2: Equipment and Tool Design INPUTS
Engineer
This defines the process developmentneeded. Lack of special features andcorrect specifications will carry over intoproduction.
DELIVERABLE
EngineerIdentifies critical features andfunctionalities that can be incorporated intoprocess and tooling design.
IMPACTRESPONSIBILITY
Buyer Updated volumes assure tools ability tomeet product requirements.
SupplierCommunicates issues identified duringthe component design review andcaptures new issues as they arise.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 2: Equipment and Tool Design INPUTS
Supplier
Supplier Updated milestones for processdevelopment.
DELIVERABLE IMPACTRESPONSIBILITY
Supplier
Preliminary concepts refined based onresults of design review.
Preliminary concepts refined based onresults of design review.
Supplier Defines all special characteristics thatneed consideration in the tooling design.
SDEOpen manufacturability issues identified inprevious phase need resolution to properlycomplete tooling design.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 2: Equipment and Tool Design OUTPUTS
Supplier
DELIVERABLE
SupplierUpdated to include process build detailsand milestones. Process realizationprogress can be measured from this.
IMPACTRESPONSIBILITY
Supplier
Final designs released to suppliersvendors for build and/or procurement of
necessary manufacturing processelements.
Updated to reflect closure of completeditems and addition of new issues thathave been identified.
EngineerUpdated to reflect resolution of suppliersmanufacturability issues, latestinformation, improved design.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 2: Equipment and Tool Design OUTPUTS
Supplier Updated to reflect progress made since
Phase 2.
DELIVERABLE IMPACTRESPONSIBILITY
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Supplier 5omponent APQP Process& 8 Phases
PHASE 3: Product/Process Realization
Applie& to ll Cte/ory A component&.
Applie& to Cte/ory G n' C component&$&e' on t!e +F;& c!oice.
Goals (click on picture to left) Guil' toolin/8 e:uipment n'or
/u/in/ nece&&ry to mnucturecomponent.
Re&olve i&&ue& i'entiie' in previou&p!&e&.
Scope (click on picture at right)
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Supplier 5omponent APQP Process& 8 Phases
PHASE 3: Product/Process Realization
Fn'& %it! t!e &upplier;& pprovl8 t t!eirven'or&; loction&8 to ccept t!e toolin/8e:uipment8 n'or /u/in/.
Ge/in& %it! completion o 'e&i/n&.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 3: Product/Process Realization INPUTS
EngineerUpdated drawings resulting fromcompleted tests and various buildscontinue to keep the supplier informed.
DELIVERABLE IMPACTRESPONSIBILITY
SupplierUpdated to reflect closure, or progress,on open issues and addition of any
newly identified problems.
SupplierFinal designs released to suppliersvendors for build and/or procurement ofnecessary manufacturing processelements.
SupplierContinuing definition of controls and, whenapplicable, expansion of detail to sub-tiersuppliers.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 3: Product/Process Realization INPUTS
Supplier
Supplier Continues to be updated to reflectprogress and/or timing related changes.
DELIVERABLE IMPACTRESPONSIBILITY
Suppliers Process FMEA contributesprocess knowledge, lessons learned,potential mistake proofing opportunitiesand other process controls to be used.
Supplier Document that defines all of the supplierscontrols starting with Receiving Inspectionand ending with the shipment to thecustomer.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 3: Product/Process Realization OUTPUTS
DELIVERABLE
SupplierUpdated to include process build detailsand milestones. Process realizationprogress can be measured from this.
IMPACTRESPONSIBILITY
SupplierUpdated to reflect closure of completeditems and addition of new issues thathave been identified.
EngineerUpdated to reflect resolution of suppliersmanufacturability issues, latestinformation, improved design.
SupplierUpdated to reflect progress made sincePhase 3.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 4: Pre-PPAP
Applie& to ll Cte/ory A component&.
Applie& to Cte/ory G n' C component&$&e' on t!e +F;& c!oice.
Goals (click on picture to left) *enerte ir&t piece& o proce&&.
I'entiy toolin/e:uipment;&
mnucturin/ cp$ility.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 4: Pre-PPAP
Fn'& %!en t!e &upplier !& &ti&ctorilycomplete' 'u&tin/ t!e proce&& topro'uce ccept$le prt&.
Ge/in& %it! &upplier;& receipt o toolin/8e:uipment n'or /u/in/ t t!eirmnucturin/ loction.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 4: Pre-PPAP INPUTS
EngineerUpdated drawings resulting fromcompleted tests and various buildscontinue to keep the supplier informed.
DELIVERABLE IMPACTRESPONSIBILITY
SupplierUpdated to reflect closure of openissues and addition of any newlydiscovered problems.
Supplier The suppliers manufacturing process andany test/measurement gauges needed.
Supplier
Defines Safe Launch Plan, where required,and documents process capability
associated with special characteristics.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 4: Pre-PPAP INPUTS
Supplier
Supplier The process developed to manufacture thematerial/component.
DELIVERABLE IMPACTRESPONSIBILITY
Document that defines all of the supplierscontrols starting with Receiving Inspectionand ending with the shipment to thecustomer.
SupplierSuppliers Process FMEA contributesprocess knowledge, lessons learned andpotential mistake proofing opportunities.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 4: Pre-PPAP OUTPUTSDELIVERABLE IMPACTRESPONSIBILITY
SupplierUpdated to reflect closure of completeditems and addition of new issues that
have been identified.
EngineerUpdated to reflect resolution of suppliersmanufacturability issues, latestinformation, improved design.
Supplier Updated to reflect progress made sincePhase 3.
SupplierThe suppliers process thatmanufactures components for serialproduction at TRW.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 4: Pre-PPAP OUTPUTS
Supplier
DELIVERABLE IMPACTRESPONSIBILITY
Document that defines all of the supplierscontrols starting with Receiving Inspectionand ending with the shipment to thecustomer.
Supplier Twelve QOS (Quality Operating System)measurables that indicate the status of theAPQP process and readiness for start-of-production.
SupplierSuppliers Process FMEA is updated toreflect any new failure modes discoveredor modify level of Severity, Occurrence
and/or Detection.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 5: PPAP
Fn'& %!en t!e &upplier;& --A-&u$mi&&ion pc
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Supplier 5omponent APQP Process& 8 Phases
PHASE 5: PPAP INPUTS
EngineerUpdated drawings resulting fromcompleted tests and various buildscontinue to keep the supplier informed.
DELIVERABLE IMPACTRESPONSIBILITY
SupplierThe process realized to manufacture thecomponent.
SDEAIAG Level 3 submission plus anyadditional needed documentation.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: PPAP OUTPUTS
DELIVERABLE IMPACTRESPONSIBILITY
Supplier
A collection of documents based on theAIAG PPAP Manual and additionalTRW requirements.
Supplier;
SDE
A scored audit designed to evaluate thesuppliers state of readiness for launch.
Supplier;SDE
For Category A and B components aformal Run at Rate is conducted to verifythe suppliers actual capacity.
SupplierThe suppliers production run that thePPAP submission will be based on.
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Supplier 5omponent APQP Process& 8 Phases
PHASE 5: PPAP OUTPUTS
DELIVERABLE IMPACTRESPONSIBILITY
Supplier Updated to reflect closure of completeditems and addition of new issues thathave been identified. All issues are tobe closed to complete the PPAP
process.
Supplier Updated to reflect progress made sincePhase 4. Full PPAP approval/releasecloses this document.
SQA;
Plant
Reviewed, and signed off on, by usingplant(s) and SQA, this initiates the SafeLaunch Plan at both the supplier andTRW.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: Supplier Development Tools Run at Rate
Found in Business Policy Manual and GSQM.
Document No: D_020_4_12
Detailed format incorporates Equipment Allocation to assure sufficientcapacity is in place to meet production requirements.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: Supplier Development Tools PPAP Requirements
Found in Business Policy Manualand GSQM.
Document No: D_020_4_18
Lists PPAP package elementsand their associated formnumbers (where applicable).
Establishes consistent order ofdocuments within the PPAP
package.
Defines different levels ofsubmission.
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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: Supplier Development Tools PPAP Checklist
Found in Business Policy Manualand GSQM.
Document No: D_020_4_19
Lists in addition to the PPAPpackage elements specific thingsto look for associated with thoseelements.
Can be used by both TRW
reviewer and supplier.Intended to drive globalconsistency in acceptancestandards for PPAP packages.
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)hen things go well and we are wor3ing together as a team, wesee great results22.
Supplier 5omponent APQP Process
8.6 5ombustion Plate 9 5ase Stud#I dont know if this was a success story, but more ofan amazing resurrection of a part that wassmoldering in the ashes
TRW Mesa Core Engineering
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8.6 5ombustion Plate
5ase Stud#
The 5.2 Inflator Combustion Plate story actually took placeafter the start-of-production.
This took place in the Summer of 2000. The OSS SDE group
had just gone through merging two different groups, Air Bagsand Seat Belts, and also had a new management team.
Many of the tools existed in pocketed areas and were notused and/or available at the programs beginning.
The component had significant issues making it virtuallyimpossible to manufacture. Demanding machiningrequirements increased cycle times to the point it wasnecessary to add several additional suppliers to meet the
requirements.
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The tools below were used to address the issues and SDE hastaken several of these and incorporated them into the globalSupplier APQP process.
Focused Design Reviews
Intensive Supplier Processing Analysis IncludingEquipment and Tool Design and Capacity
Run at Rate and Contingency Plans
Cost of Quality and Yield Analysis
Engineering Collaboration for Design for Manufacturability
8.6 5ombustion Plate
5ase Stud#
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econ'ry
-ropellnt C!m$er
Retention tu'
Com$u&tion-lte
InititorRetiner
Cni&ter+iu&er
Inititor
-ropellnt
Fn!ncer-ropellnt
Rupture +i&;68
5hange B :=@ chamfer
tool to spot drill
Tool change should result in a 8 sec. advantage $S( to order tool and test b#
>;C.
(ncrease %P$ on bottom endmill
Speed change should reali;6.
"#pass autoload operation Autoload operation potentiall# less efficient than
operator positioning:estimated savings of 8 sec.
$S( to perform trial run onfifth )asino and evaluateonce machine is running.
Actions were defined based on the studys results.
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8.6 5ombustion Plate
5ase Stud# : %esolution Activit#& Suppl# 5hain
rition intro'uce' into t!e proce&& $y &tmpin/ net or/e' prt.
"ltimtely t!i& trn<e' into 'iiculty in mintinin/ true po&ition or t!ei/niter port&. A ne% 'tum Mpt&.N %oul' nee' to $e ''e'.
StampedFeatures
MachinedFeatures
Added additionaloperation tomachine flats to
create fixturinglocation toensure trueposition
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8.6 5ombustion Plate
5ase Stud# : %esolution Activit#& 'auging
100J *u/in/ %& re:uire' on t!e $uttre&& t!re'& Mn/ulr tolernceor inititor orienttionN $ecu&e o t!e lr/e mount o yiel' lo&&.
*u/in/ %& perorme' %it! t!re'e' in&ert& &!o%n $elo% %!ic!:uic
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8.6 5ombustion Plate
5ase Stud# : %esolution Activit#& 0*cessive "urrs
Burr Locations
-on'& M'e&i/ne' or %ei/!t re'uctionN %ere eliminte'. pecil 'e$urrin/ tool& %ere 'evelope' to llo% opertor& to rec! t!e
$urr loction& n' remove $urr&.
T!erml 'e$urrin/ met!o'& %ere e@plore'.
ec!nicl 'e$urrin/ n' relie n/le& or toolin/ %ere e@plore'.
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8.6 5ombustion Plate
5ase Stud# : %esolution Activit#& 5#cle Time Anal#sis
F@ten&ive nly&i& %it! e:uipment provi'er to i'entiy /p& in:uote' ver&u& ctul cycle time to perorm &peciicopertion&. T!i& re:uire' 'o%nlo'in/ o C?C co'e Mcnnot&ee opertion in clo&e' c!m$erN.
Anly&i& &!o%& t!t only 3 out o ) opertion& %!eree@pecte' to meet &c!e'ule t!i& %& prtly 'ue to vriou&&econ' &ource& n' t!e in$ility to clerly communicte&c!e'ule re:uirement&.
Anly&i& clerly &!o%& t!e improvement re:uire' in term& o''itionl e:uipment n' t!e u&e o improve' i@ture& toeliminte nee' or reDc!uc
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8.6 5ombustion Plate
5ase Stud# : %esolution Activit#& 5#cle Time Anal#sis
5urrent
The bottleneckoperation produces
less than the needvolume
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8.6 5ombustion Plate
5ase Stud# : %esolution Activit#& 5#cle Time Anal#sis
5urrent
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8.6 5ombustion Plate
5ase Stud# : %esolution Activit#& 5osts
A co&t mo'el %& 'evelope' to en&ure 3r'mnucturin/ &ource %oul'inclu'e ccurcy in t!e co&t &tructure o t!e component n' oer competitive price. MI %& &
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)hat do we need to fi*22
Supplier APQP Overview
Supplier APQP follows the pareto principle. That is 20% of thecomponents require 80% of the effort.
Full, cross-functional participation is required at the following events: Component Priority Assessment
Supplier Kick-off Meeting Component Design Review Launch Readiness Audits
Manufacturable designs, with clearly defined special characteristics,sufficiently early in the program to assure suppliers can build and tune-
in their processes to meet drawing expectations and requirements.
Ownership of the suppliers by the launch team.
Escalation of show stopper issues to upper management within theproduct lines.
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ucce&&ul component A-- i& cro&&Dunctionl eort.
TRW upplier +evelopment !& %ellD'eine' tool$o@ t!t i /iven
&uicient re&ource& n' &upport cn ''re&& n' re&olve &i/niicnt
i&&ue& $eore &trt o pro'uction.
=or t!e 20J o t!e component& t!t my criticlly ect ny lunc!8
lc< o &uicient inormtion or i&&ue re&olution erly in t!e proce&&%ill cu&e i&&ue& 'urin/ lunc! n' &eril pro'uction.
APQP Summar#
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QUESTIONS?
?