APQP Advanced Product Quality Planning Supplier · PDF file3 Agenda APQP: Polaris Internal Training Module Learning Objectives The Process Flow –the When and How The What, When,

Process Training - Supplier

APQP – Advanced Product Quality Planning– Supplier Quality

Revised: January 5, 2015

Revision Number: 1Polaris CONFIDENTIAL

2

Welcome

Welcome!Polaris CONFIDENTIAL

Welcome to the Advanced Product Quality Planning (APQP) Polaris Supplier

Training Module.

This module will allow you to better understand the requirements, expectations

and process for delivering new products and/or parts to your customer with

great success through the use of APQP.

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Agenda

APQP: Polaris Internal Training Module

Learning Objectives

The Process Flow – the When and How

The What, When, Who of APQP

Training Content

Tools and References

Demo / Example

Learning Objectives Recap

FAQ

Thank you!

Polaris CONFIDENTIAL

4

Learning Objectives

Focus on the objectives and ask questions throughout!!

At the end of this training, participants will be able to:

• Understand the overall process of APQP and when you are required to utilize

the APQP process.

• The importance of a standardized method for APQP

• Guidelines for APQP

• How to use the APQP process.

Polaris CONFIDENTIAL

Critical Process Steps:

This will be your guide in the presentation to give you an understanding of APQP

topic and its benefits to you.

Process Usage:

High Level Part Risk Identified

pre G2

Heat Map to drive APQP

Level (H/M/L)

SQE Project Leader assigns

key dates

APQP Project Kicked off with

Supplier

Supplier and SQE collaborate

to submit and approve key

elements

Project SOPEnd APQP with Phase 5 review

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Process Overview

APQP is integrated with PDP (Polaris Development Process)Polaris CONFIDENTIAL

P

P

A

P

Supplier

QualificationPDP

EOL

Safe Launch

Supplier Performance

Product

Assurance

ControlMonitoring Improvement

APQPQuality Event

Resolution

Supplier On-

Boarding

The Quality Lifecycle Management process is a

process to ensure product quality assurance.

………….Serial

Production…….………MaturityVolume Ramp….SOP PPAP…..APQP……

SupplierSelection

What is APQP?

Advanced Product Quality Planning is a structured method of

defining and establishing the steps necessary to assure that a

product satisfies the customer’s needs and that failure

modes are identified and mitigated early in development

process

Hard to Find

Easy to Fix

Failures

Easy to

Find

Hard to Fix

Failures

Guiding Principles

The AIAG Advanced Product Quality

Planning (APQP) and Control Plan

Reference Manual [available at aiag.org] provides

the general guidelines for ensuring that

APQP is implemented in accordance with

the requirements of the customer.

The APQP spreadsheet used by Polaris

includes the corresponding page number

referencing each of the APQP steps for

quick orientation

Why do APQP?

Advanced – start early, with concepts, drive

collaboration from onset

Product – focus on the product and the

customer needs/requirements

Quality – Get it right the first time, efficiently and

every time, build quality in from concept

Planning – Collaboration will drive a robust plan

and a superior product launch

Who has responsibility within APQP?

Project Lead SQE – Assigns key dates (gates) and measures progress of

entire program

SQE’s – Facilitate APQP activities with suppliers, help to pull in PII resources,

coordinate joint activities, keep project on task, support the supplier

Plant Quality – Support suppliers, SQE’s, design engineers, etc through the

course of APQP. Play pivotal role in customer needs and PPAP approval.

Engineering – Execute assigned APQP activities, participate in design

reviews, FMEA reviews, etc and support supplier for DFM activities

Purchasing – Assist in APQP activities, support entire team and collaborate as

necessary to ensure tasks are completed on time and accurately

Supplier – Execute APQP activities, on time, thoroughly to

prepare for a successful launch

Execute to the plan


pre G2


Level (H/M/L)


key dates


Supplier



elements


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Narrow full BOM to critical few parts with greatest risk to program

What Parts get APQP?

BOM Parts

New/Revised Parts

Group 1, Group 2 Risk Parts

Critical Parts

APQP

Parts

Identify parts that

are Safety- or

Performance-Critical

All Group 1 Risk Parts + Group 2

Parts that have new/problem

supplier or historically problem

part

Highest risk critical parts

Parts follow detailed

supplier selection

process. Risk

communicated through

heat map

Part status managed

and communicated

through APQP

Plan/Report Card

Sourced

Product

Risk

Analysis

Project-

Level Heat

Map

Part Risk Management Funnel


pre G2


Level (H/M/L)


key dates


Supplier



elements


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Sourced Product Risk Analysis Heat Maps APQP Plan

Supplier Risk Management Framework

Maintain throughout program

Gate 1 CSR Gate 2 SOP

Maintain throughout program

APQP Level Selection

Level M is for manually selecting requirements

based on project, part and/or supplier need

Levels 1 – 3 are minimum APQP requirements

as determined by Polaris, other value added

APQP steps may be selected by the

Supplier/Polaris cross functional teams

Level M –Manual

• 63 Total Potential APQP Steps to Select

Level 1 – Low Risk

• 21 Mandatory APQP Steps Selected

Level 2 –Medium Risk


Level 3 –High Risk


0.0

2.0

4.0

6.0

8.0

10.0

0.0 5.0 10.0Co

mm

od

ity

Ris

k

PII Impact

Risk Assessment


pre G2


Level (H/M/L)


key dates


Supplier



elements



pre G2


Level (H/M/L)


key dates


Supplier



elements


How the Key Dates are Selected

Key dates are selected based off of PDP gate milestones and key

build dates and assigned by the lead PII SQE

Gate 2

V (Validation) Build

PDP Design Review

PI (Production Intent) Build

PV (Process Verification) Build

Gate 3

SOP

All dates between milestone dates are to be agreed upon by Polaris

and Supplier and must meet key Gate dates.

Key Dates are selected by Polaris – Activity Dates selected by team

Supplier APQP Kickoff

The Kickoff meeting is one of the most important events

for a supplier working on APQP.

Objectives of Kickoff:

• Establish Part List

• Establish Core Team

• Communicate key dates and JOINTLY select activity dates

• Agree upon a review / submittal cadence

• Determine escalation path if project goes off track

Kickoff meeting is critical to project success


pre G2


Level (H/M/L)


key dates


Supplier



elements



pre G2


Level (H/M/L)


key dates


Supplier



elements


Fulfilling the Requirements

Be thorough in your document review before submitting

Add completion percentage to cover sheet: when 1.0 is

entered, SQE will review that element and sign off or send

back comments/feedback

Add non-data intensive elements to the workbook tabs

For data intensive elements, add cover sheet to tab and

send actual documents to SQE via Email

How to use the APQP spreadsheet


pre G2


Level (H/M/L)


key dates


Supplier



elements






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

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

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

Rev 6.1


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

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

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

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

be preapproved by Polaris ahead of time by obtaining a GOLD square

The Polaris SQE is saying, “This document is ready for PPAP submission”


PDP Status Tab of Workbook

Provides a Snapshot of PDP Progress by the

Supplier

Populated from APQP Spreadsheet


pre G2


Level (H/M/L)


key dates


Supplier



elements


SOP - PPAP

One core outcome of APQP is a first pass of the PPAP

Collaboration between Supplier and Polaris should aid in this successful PPAP approval

Submit early if possible

The primary outcome is successful production launch

Success = PV builds with no major quality spills, SOP builds with no quality spills, fulfilled safe launch period, no line down situations, no field actions

APQP Successful SOP

APQP Tracking goals and metrics in place; PDP deliverables defined24

How is APQP Tracked?

APQP Report Card

1. Queries existing APQP workbooks that are populated by the supplier quality team

2. Tracks APQP completion % vs. plan; along with Critical task completion

3. Automatically color codes data points based on % off plan.

4. Table on left side displays supplier level detail

5. Part-level detail is available through a link to supplier’s APQP workbook


pre G2


Level (H/M/L)


key dates


Supplier



elements


Project Completion - Phase 5 Review

Lessons Learned

Variation Reduction Plans

KPC Improvement / Monitor Plans

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As a Polaris Supplier, you should understand:

• Understand the overall process of APQP and when you are required to utilize the APQP process.

• The importance of a standardized method for APQP

• Guidelines for APQP

• How to use the APQP process.

Learning Objectives Recap

Are you comfortable with the APQP process?Polaris CONFIDENTIAL

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Thank you!

Thank You!Polaris CONFIDENTIAL

Thank you for taking the time to complete the APQP Polaris Training Module.

Questions? Please contact your key Supplier Quality or Development Engineer!

Documents

APQP Advanced Product Quality Planning Supplier · PDF file3 Agenda APQP: Polaris Internal Training Module Learning Objectives The Process Flow –the When and How The What, When,