NAVISTAR APQP

8/12/2019 NAVISTAR APQP

1/18

Date:

X

Does the Supplier have the latest information about program timing (examples include Drawing release, Prototype, PPAP date

required at plant date, Start of Production, Volumes)?

Does the Supplier understand all the applications and intended end uses of the parts/materials for all customers?

Copies musAPQP Kickoff Meeting

Explain:

Explain:

2.1 Yes No Does the Supplier have and understand ALL of the latest drawings and specifications, including CEMS B-50?

SECTION 2 - PRODUCT DESIGN / DEVELOPMENT

Explain:

2.2 Yes No

Explain:

1.6

Does the Supplier have and understand all the requirements listed in the Navistar Integrated Supplier Quality Requirements, N

other Navistar requirements (e.g. appearance item approval and CEMS B-50)

Does the Supplier have copies of the latest versions of and understand the ISO 9001 and, if applicable, ISO/TS 16949 quality

standards, the AIAG manuals (APQP, PPAP,FMEA, SPC, MSA) and, where appropriate, the AIAG CQI special process manu1.3 Yes No

1.5 Yes No Does the Supplier understand the requirements of Navistar Packaging Specification D-13?

1.4 Yes

Explain:

Explain:

1.8 Yes No Is the Supplier ready to receive Navistar EDI orders?

Yes No Are returnable containers required?

Explain:

1.7 Yes No Are there any packaging issues left to resolve (such as alternative packaging, dunnage, protective sleeves)?

This document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

Part number(s):

No

Explain:

Part Description:

Supplier Name:

Supplier Code:

1.1 NoYes

Date Key Project Milestone

SECTION 1 - CUSTOMER REQUIREMENTS

Explain:

1.2 Yes No

Explain:

Key Project Milestone

Review Key Project Milestones with Supplie

If Navistar is design responsible, has a Design-FMEA review been completed with the Supplier and the Navistar Engineer and

available?

Supplier Location:


2/18

Date:

X

Copies musAPQP Kickoff MeetingThis document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

Part number(s):

Part Description:

Supplier Name:

Supplier Code:

Supplier Location:

Key Act iv i t ies from the APQP Project Plan

Explain:

No Are any new equipment, tooling, gages, special fixtures or test equipment needed to produce this part?

Supplier Promise DateQuantity

No Will the appropriate control plan be developed for use during each build (e.g. NPD build events, Prototype, Pre-Launch, and P

Explain:

3.1 Yes No Has the Supplier filled out, updated and submitted the Navistar APQP workbook for these parts?

Explain:

Yes NoIf Supplier is design responsible, has a Design-FMEA been updated as necessary? Are actions in place to reduce high RPNs?

been reviewed with the Navistar Engineer?

2.3 Yes No

Explain:

Explain:

3.3 Yes No Has error proofing been considered during PFMEA development and included in quoted price?

Explain:

SECTION 3 - PROCESS DESIGN/DEVELOPMENT

3.2 Yes No Has the Supplier completed APQP plan entries into the Navistar New Part Tracking (NPT) System, if applicable?

Explain:

2.7 Yes No

2.4

Explain:

2.6 Yes No Are there any Pre-Prototype/Prototype requirements?

2.5 Yes No

Explain:

Does the Supplier understand the requirements of the Navistar procedure (with Phased PPAP) for prototype parts and the req

prototype parts must be inspected, verified and validated that they meet design intent?

Explain:

3.4 Yes

2.8 Yes

If Navistar is design responsible, have YC, YSs from the DFMEA been analyzed, and decisions made to include in PFMEA &

Supplier aware AIAG FMEA Manual? Is the Suppliers intended process able to meet the capability requirements of the CCs,

If Supplier is design responsible, has the IQA (Installation Quality Assurance) been submitted to and approved by Navistar R&

Vehicle systems (Brakes, Transmission, Engine, Steering, Radiators, Fan Drivers, SCR, Batteries) and Engine Systems (Fuel

Cooler, Turbo, Intake Throttle, Damper, Flywheel).

List them below:

Prototype Material Required Date


3/18

Date:

X

Copies mustAPQP Kickoff MeetingThis document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

Part number(s):

Part Description:

Supplier Name:

Supplier Code:

Supplier Location:

3.8

3.9

3.10

3.11

4.1

5.2 Yes NoDoes Supplier understand the requirements for controlled shipping level 1 and 2 and Navistar Quality Top Focus program? Ar

on controlled shipping status?

Explain:

Explain:

Explain:

A. Daily Contracted Capacity

B. Number of tool sets required

C. Number of machines/lines/cells required

D. Capacity per tool set

Explain:

3.17 Yes NoDoes the Supplier understand that the exit strategy to return to the normal Control Plan is: no defects during the first 90 days;

SC's at PPAP and 1.33 Ppk for each of the first three months of production?

EARLY PRODUCTION CONTAINMENT

Explain:

4.2 Yes No Does the Supplier understand the Navistar Capacity Planning Verification process?

E. Number of work hours per day

F. Number of shifts per day

G. Number of days per week

Enter estimated PPAP Submission Date:

3.12

3.13

3.14

3.15

3.16 Yes No Does the Supplier understand that the Pre-Production Control Plan (with extra tests, examinations will remain in place until Job

Enter number of Cavities / Molds to submit for PPAP:

Enter number of Cavities / Molds to submit for PPAP:

Enter number of parts per Cavity / Mold in PPAP production run:

Explain:

3.7 Yes No Has the Supplier confirmed that their subcontractors will do the following?: PPAP

Enter lead time for tooling (wks):

Enter date for first production run & submission of PPAP:

Submission Level (1- 5)

Explain:

3.6 Yes No Has the Supplier confirmed that their subcontractors will do the following?: APQP

3.5 Yes NoNavistar's minimum required acceptance criteria for the PPAP initial study is a Cpk or Ppk of 1.67 (ref. AIAG PPAP manual). A

specifications or process control plan changes needed to meet these requirements?

SECTION 4 - RUN @ RATE & CAPACITY RELATED

Explain:

4.3 Yes

Enter the name of the person you will submit PPAP to:

SECTION 5 SUPPLIER QUALITY PERFORMANCE

5.1 Yes No Does the Supplier understand the Navistar Global 8D requirements and are there any unresolved Global 8Ds?

Explain:

NoDoes the Supplier understand that Navistar pays for tooling only upon successful completion of PPAP with Capacity Verificatio

Supplier can meet the daily contracted capacity?


4/18

Date

X

CopieAPQP Kickoff MeetingThis document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

Part number(s):

Part Description:

Supplier Name:

Supplier C

Supplier Location:

Explain:

NoHas an NSA (Navistar Supplier Assessment) been completed? If so, what was the score and classification? Are the corre

closed?

Supply Manager

Manufacturing EngineeMaterials Representative

Plant Quality Manager

Product/Design Release Engineer

Yes

Explain:

5.4

Quality Manager

Program Manager

Date:

Quality Engineer

5.5

Explain:

Advanced Supplier Quality Engineer

Navistar Attendees:

What is the Suppliers current R/1000 or PPM for current customers with similar products:

Supplier Attendees


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Report Date:

Part Number:

Current Last Trend

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A lProgram Manager Date

Product and Process Validation (Phase-1 Parts)

GYR Status

Tooling

Customer Contact Names Entering the Team

Pre-Production Process Failure Mode Analysis

APQP Element

Date for the Te

Entering the Team Leaving the Team

CopieNavistar Advanced Product Quality Planning - Worksheet and Report

Customer:

Supplier Name:

Supplier Team Members

Part Name:

Program:Navistar Inc.

Responsibility

Leaving the Team

Resp.

Initials

Program

Need

Date

Planned

Date

Prototype Build Control Plan

Operator Inspection and Process Instructions

Logistics (Internal and External)

Production Readiness Review

Process Capacity Sign-off

Product and Process Sign-off (Phase-2 Parts)

Pre-Production Control Plan

Preliminary Capability Studies

Planned Maintenance and Key Spares Requirement

Design DVP&R

Measure and Test Equipment

Preliminary Bill of Materials

Design Failure Mode Analysis (DFMEA)

Sub-Supplier Direct Materials / Prototypes

Sub-Supplier Tooling and Equipment

Utilities Plan, Layout Plan & Manpower Plan

Capital Equipment Plan

Prototype Process Flow Diagram

Pre-Production Process Flow Diagram

Design Review

Closed

Date

Responsibility

Production Test and Measuring Equipment

Drawings and Specifications

Preliminary Process Flow Diagram

Packaging (Internal and External)

Safety & Environment

Design Verification Requirements

Prototype Process Failure Mode Analysis (PFMEA)

Design Verification Test Review


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Project

ElementKey Requirements Current Last Comments

1) Design Review Eleme

1.1Does the documentation show that all design changes are approved by

the customer?

1.2Have all design changes been incorporated into the latest specifications

and drawings?

1.3Do design changes have an impact on the timing plan and the customer

Material Required Dates?

1.4Do design changes have an impact on the time and costing of

manufacturing run at rates?

1.5 Have design reviews been conducted with manufacturing?

2) Drawings and Specifications Eleme

(received from Navistar)

2.1.1Is a complete set of drawings (schematic, mechanical, layout) available

and released for the latest level product?

2.1.2 Does the supplier have the latest specification and test requirements?Where appropriate, have these been flowed down to the sub-suppliers?

2.1.3Have 'Significant Characteristics' and Pass Through Characteristics

been agreed to?

Manufacturing

2.2.1Has the Feasibility Commitment been completed and signed as

evidence of that the product can be produced?

2.2.2Have current manufacturing drawings been issued internally / Sub-

supplier plant?

2.2.3Have all specifications and drawings been agreed by the manufacturing

source?

2.2.4Have all dimensions that affect fit, function and durability been identified,

and are they fully understood, and agreed?

3) Preliminary Bill of Materials Eleme

3.1Is the Bill of Materials complete and costed, Does it meet the business

target?

3.2 Are component standards defined?

3.3 Is the BOM full volume capable?

3.4 Is the BOM available and released?

4) DFMEA Eleme

4.1Has the initial DFMEA been compiled. Are the functions needed

reviewed by a Cross-Functional team?

4.2Have Customer Significant Characteristics / Key Characteristics been

identified?

4.3

Has historical product and warranty data been considered. Have

failures at Concept Verification / Design Verification testing been

considered?

4.4Are risks identified for meeting durability and reliability goals. Where

identified are plans in place to reduce risks?

4.5Have high RPN's been addressed, corrective actions defined, reviewed

and verified?

4.6 Is there a pareto of high RPN's available?

4.7 Has the DFMEA been reviewed after design and / drawing revisions?

4.8 Is the DFMEA in-line with drawing revisions?

4.9 Has the customer reviewed the current DFMEA?

5) Design Verification Requirements Eleme

5.1 Is the design in accordance with the functional requirements?

5.2 Is a complete set of drawings (schematic, mechanical, layout) available?

DesignC

Status GYRIf NOT APPLICABLE Element is left blank


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DesignCo


5.12 Are the manufacturer and test of prototypes identified?

5.13 Are the sample requirements understood for timing and quantity?

6) Design DVP&R Eleme

6.1 Does the DV test plan meet the customer requirements?

6.2 Has DV testing passed successfully?

6.3 Do the DV results meet the customer specification requirements?

6.4Are failed items during production validation testing covered by

corrective actions (8D); are corrective actions verified and retested?

7) Design Verification Test Review Eleme

7.1Are there any significant design changes from test level (drawings and

specifications)?

7.2 Are the drawings / specifications / BOM released?

7.3 Is the Design FMEA in line with the drawing revision?

7.4 Are test parts representative of a production source?

7.5Have all specifications and drawings been agreed by the production

source?

7.6 Are the chosen designs and processes capable of mass production?

7.7Have high RPN's at the Design FMEA from the CV review been

resolved?

7.8 Have any new high RPN's shown up during the CV level phase?

7.9 Are risks identified (function, manufacturing, durability, timing, costs)?

7.10 Is the Design now frozen or are further tests required?


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Project


8) Preliminary Process Flow Diagram Elem

8.1

Does the flow chart show all operations, control points from receiving to

shipping; Is the planned manufacturing flow adequate and without major

risk?

8.2

Are critical processes, control points for customer designated

characteristics and / or critical processes / product characteristics

included and highlighted?

9) Utilities Plan, Layout Plan & Manpower Plan Elem

9.1Does the floor plan have clearly marked areas for all materials, tools,

and equipment at each operation?

9.2 Has sufficient space been allocated for all equipment?

9.3 ere e a equa e servces e.g. e ec r c y, compresse a r

available on time?

9.4

Have controls been established to eliminate the potential for an

operation, including outside processing, to contaminate or mix similar

products?

9.5 Is material protected from overhead or air handling systemscontamination?

9.6Are inspection points logically located; adequate for staging and hold

areas?

9.7

Is there a recruitment and training plan that meets the needs of ramp-up,

and production processes at full 'run at rate' that includes quality

inspection and maintenance support?

9.8Is there a training matrix by employee skill level showing numbers and

training required?

10) Capital Equipment Plan Elem

10.1Is the timing plan for new manufacturing equipment developed, reviewed

and monitored?

10.2 Does the procurement and installation meet the customer timingrequirements?

10.3 Have purchase orders been approved and released?

10.4Are run off with intended production rates scheduled and carried out at

equipment suppliers. Results meet capacity and quality targets?

10.5Does run off at manufacturing installation meet the process parameters

as defined at production rates scheduled?

10.6

Have capability studies been scheduled and carried out at manufacturing

site, measurements done in representative quantities, with results that

meet the customer requirements?

11) Tooling Elem

11.1 Is the timing plan for new tooling developed, reviewed and monitored?

11.2 Does the procurement and installation meet the customer timingrequirements?

11.3 Have purchase orders been approved and released?

11.4 Does timing include try out and optimization?

11.5

Have capability studies been scheduled and carried out at manufacturing

site, measurements done in representative quantities, with results that

meet the customer requirements?

11.6 Is try out and optimization complete?

12) Measuring and Test Equipment Elem

12.1Is all measuring and test equipment identified, is it included in the timing

plan?

12.2Have all test and measurement equipment requirements been defined

and communicated to suppliers?

12.3 Is the procurement and installation of measurement equipment on time?


Plant + Process


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Plant + Process

14) Prototype Process FMEA Elem

14.1Is the Process FMEA started, are the functions needed part of the FMEA

team

14.2 Is a pareto available of high RPN's. Is the severity ranking consistentwith the DFMEA and the customer significant characteristics?

14.3 Have corrective actions been defined, reviewed and verified?

14.4 Does the match the Process Flow?

15) Prototype Control Plan Elem

15.1 Does the control plan include the customer significant characteristics?

15.2 Does the control plan match the Process Flow and PFMEA

15.3Are sample sizes for dimensional measurements, material and functional

tests adequate for prototype builds?

15.4Does the control plan address incoming (material / components) through

processing / assembly including packaging?

16) Operator Inspection / Process Instructions Elem

16.1 Are work instructions complete and released?

16.2

Are instructions available on how to proceed with non-conforming

material; i.e. Analysis, rework, disposition of NC material / returned

material?

16.3 Are instructions available for machine / job set-ups?

16.4Are inspection instructions available that define checking frequencies,

sample sizes, acceptance standards and test specifications?

16.5Are methods and facilities available for recording inspection / test

results?

17) Logistics Internal / External Elem

17.1 Is the customers schedule known and understood?

17.2 Does the delivery frequency agree with the customer RFQ?

17.3 Has a transport provider been agreed?

17.3 If required; Has a Logistics FMEA been completed, and updated?

17.4 Has internal transport, WIP controls, storage space, etc. been defined?

18) Packaging Internal / External Elem

18.1Has a packaging and logistics trial been scheduled to assess risk for

handling, cleanliness, damage, identification and procurement costs?

18.2

Will sufficient packaging be available for a significant production run and

support full volume production?

18.3Has a packaging / labeling specification been raised, agreed and

released by the Customer?

19) Safety and Environment Elem

19.1Are there any customer or regulatory requirements for the notification of

hazardous substances e.g. MSDS and IMDS requirements?

19.2Has Navistar CEMS B-50 been taken into account during product and

process design?

20) Pre-Production Process Flow Diagram Elem

20.1

Does the flow chart show all operation, control points from incoming

goods to dispatch; Is the planned manufacturing flow adequate and

without major risk?

20.2

Are additional checks in place for pre-launch activities for critical

processes, control points for customer designated characteristics and /

or critical processes / product characteristics included and highlighted?


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Plant + Process

22) Pre-Production Control Plan Elem

22.1Does the pre-launch Control Plan include additional activities such as

increased inspection, in-process and final check points?

22.2Are these addition pre-launch controls monitored by SPC or 100%inspection for customer Significant Characteristics and Key Production

characteristics?

22.3Does the Control Plan track the process steps in the Process Flow chart

and the PFMEA?

23) Preliminary Capability Studies Elem

23.1Have short term studies been carried out that provide statistical data to

show process capability.

23.2Have preliminary process capability studies been performed on the

characteristics identified in the Control Plan.

24) Production Test and Measuring Equipment Elem

24.1Has test and measuring equipment been identified, is it included in the

timing plan and progress being monitored?

24.2Have all test and measurement requirements been defined and

communicated to the suppliers?

24.3Is procurement and installation of test and measurement equipment on

time?

24.4

Are detailed test and inspection operator instruction available on the

manufacturing site, are the operators trained in the use of instructions

and recording methods?

24.5Have provisions been made to certify and routinely calibrate measure

and test equipment?

24.6Has Measurement System Analysis been carried out on all inspection

and test equipment on the control plan to evaluate product?

24.7Where MSA results are not acceptable is there a corrective action plan

in place to meet compliance?

25) Planned Maintenance and Key Spares Requirement Elem

25.1Has all production equipment and tooling been included in the PM

program?

25.2Have all key spares been identified that ensure production is optimized

to prevent show stoppers?

25.3Are manning and necessary trained personnel available to maintain

volume production?

26) Production Readiness Review Elem

26.1Has all Design Validation passed testing and been approved by the

customer?

26.2Are all Design Validation documentation complete and DV issues / 8D's

closed with countermeasures in place?

26.3 Have all component and assembly drawings been updated andreleased?

26.4Are customer specification complete (software and function) and

requirements frozen?

26.5Has all production documentation been completed and released to

manufacturing?

26.6Has the Production trial run been scheduled with adequate quantity of

parts that represents Production Rates

26.7Has the Process Flow / PFMEA and Control Plans been completed,

reviewed and approved?

26.8Are all necessary inspection gages job set-ups and operator instructions

in place to support production?

26.9Are product control points in place including identification of non-

conforming and reworked product?

26.10 Are all production processes been production tooled?


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Cop


Plant + Process

29) Product and Process Sign-off (Phase-2 Parts) Element

29.1 Are all activities on time to achieve Parts Submission Warrant (PSW)

29.2Is all Production Parts Approval Process (PPAP) documentation

complete and readily available?29.3 Has the customer signed the PSW authorizing shipment?


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30) Sub-Supplier Selection - Direct Materials Eleme

30.1.1 Has a Sub-supplier been selected, are parts identified?

30.1.2 Have long lead and high risk suppliers been identified, has a plan tomanage them been developed?

30.1.3Have all specifications and drawings been raised, completed and

released?

30.1.4Is there a matrix of all purchased in assemblies / components and is this

reviewed?

30.1.5 Were applicable, are suppliers APQP / PPAP status to plan?

Sub Supplier Selection - Prototypes

30.2.1 Has a Sub-supplier been selected, to build outsourced Prototype Parts?

30.2.2Have current manufacturing drawings been issued internally and Sub-

supplier plant?

30.2.3Have all specifications and drawings been agreed by the prototype

manufacturing source?

30.2.4If testing of prototypes is outsourced, does the supplier fully understand

and agree the DVP&R requirements?

30.2.5Have all dimensions that affect fit, and function been identified, and are

they fully understood, and agreed?

30.2.6

Has a manufacturing feasibility commitment been agreed that the

Prototype design can be manufactured, assembled, meet required

material dates and quantities?

31) Sub-Supplier - Capital Equipment Eleme

31.1.1 Is a capital equipment timing plan developed, monitored?

31.1.2 Have capital equipment suppliers been identified and documented?

31.1.3Have long lead and high risk suppliers been identified, has a plan to

manage them been developed?

31.1.4Have capital equipment specifications (including capability

requirements) been raised and released?

31.1.5Are try-out schedules at supplier / manufacturing site agreed and

understood.

31.1.6 Where applicable, are suppliers APQP status to plan?

Sub Supplier - Tooling

31.2.1 Has a tooling timing plan been developed, monitored?

31.2.2 Have tooling suppliers been identified and documented?

31.2.3Have long lead and high risk suppliers been identified, has a plan to

manage them been developed?

31.2.4Have tooling equipment specifications (including capability

requirements) been raised and released?

31.2.5 Where applicable, are suppliers APQP status to plan?

Co

If NOT APPLICABLE Element is left blank Status GYR

Sub-Supplier


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EARLY PRODUCTION C

Supplier -- Cpk Values Supplier:Submission Date: Part number:

Rev. Level:

Special Characteristics

Tolerance/ Sketch

Test Method/Measuring

Equipment

Gage R&RTest/ Sample

SizePpk - Chart

e

0

1

2

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4

5

Ppk -- Values

0

1

2

3

4

5Ppk -- Values

0

1

23

4

5

Ppk -- Values

0

1

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5

Ppk -- Values

0

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Ppk -- Values

3

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Ppk -- Values


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Rev. No. Effective Date Revision HistoryA 11/1/2012 New form ISQ-005-FO for ISQ (KdW, 10/19/2012)

B 3/8/2013

Fixed functionality issues related to form function. Changed

checkboxes to individual cells. Removed the shading.

Removed PTC Analysis From and Capacity Verification Forms.

Documents

NAVISTAR APQP