S-APQP

Supplier Advanced Product Quality Planning (S-APQP) S-APQP-Revision-Level: Last Revision-Date:

Supplier Name:Location:

Part Name:Part Description:

Autoliv Part No. / Rev.:Autoliv Drawing No.:

Project Team (Supplier)

# Name Function Phone123

Project Team (Autoliv)

# Name Function Phone123

Pre-Production delivery schedule Date

123

Review meetings Autoliv / Supplier Date

123

B18

Please use the function 'Insert Line' to add a additional line at this section. Please use the function 'Delete Line' to delete a line at this section. One row at this section is the minimum.

B24


B29


B34



Confirmation that current revision of the S-APQP plan reflects the current project status.

Project Team Leader Supplier Signature Date

Commitment to launch and complete the project according to the S-APQP planning.

Management representative Supplier Signature Date

Notes

B50



Calendar Year

# Activity Supplier Resp.Ready Status Calendar Year

20% 40% 60% 80% 100% Status January

Red Yellow Green Completed ###

1 Project Team

2

3 Contract Review

4

5 Prototype delivery schedule

6

7

8 Special characteristics

9 Substance review

10 Reliability / Quality prediction

11 Software validation plan

12

13

14 Lot Traceability Plan

15 Process flowchart

16 Process FMEA

17 Control Plan

Planned Start-Date (YYYY-MM-DD)

PlannedDue Date

(YYYY-MM-DD)

Actual Start-Date (YYYY-MM-DD)

Actual Completion-

Date (YYYY-MM-DD)

Follow-up / Comments / References

Feasibility Study and Action Plan completed

Serial Order and Drawings / Specification release

Sub-supplier (material and sub-components) APQP and assessment

Design-FMEA (only if design responsible)

Material / Performance validation plan

Design Verification (only if design responsible)

E9

Please use only valid date formats, e.g. YYYY-MM-DD: 2004-04-01 DD.MM.YY: 01.04.04 MM/DD/YY: 04/01/04

F9


G9

Double click at the related Status column (20%, 40%, 60%, 80%, 100%) of the Activity row to change the Ready Status. If the Status is 20%, then double-click at 20% once again to set the Ready Status to 0%.

M9


N9



Calendar Year


20% 40% 60% 80% 100% Status January



PlannedDue Date

(YYYY-MM-DD)


Actual Completion-

Date (YYYY-MM-DD)


18 AS2 Process Audit

19 Facilities and Process Equipment

20 Measuring and Control Equipment

21 Production tooling procurement

22

23 Training

24

25 Maintenance Plan

26 Engineering Sample Approval

27 Appearance approval reports (AAR)

28 Sub-supplier PPAP

29 Special Processes

30

31

32 Measurement System

33

34 Product / Production Validation

Work instructions / Inspection instructions

Material Handling and Packaging Instructions

First-Production-Trial-Run and Corrective Actions

PPAP-Production-Trial-Run and PPAP-Package Preparation

Initial Capability Studies and SPC Plan

E9


F9


G9


M9


N9



Calendar Year


20% 40% 60% 80% 100% Status January



PlannedDue Date

(YYYY-MM-DD)


Actual Completion-

Date (YYYY-MM-DD)


35 PPAP Submission

36 Run at Rate

37 SOP

38 Early Production containment

39 Design Reviews

E9


F9


G9


M9


N9


1 Project Team

2 Feasibility Study

3 Contract Review

4 Serial/Tool order and Drawings / Specifications ReleaseThe date for serial/tool order shall be defined and included in the S-APQP.

5 Prototype Delivery Schedule

6 Sub supplier APQP

7 Design FMEA

Assignment of responsibility to a supplier cross functional team and a team leader with full commitment and support from supplier upper management.

The supplier project team shall perform a feasibility study to verify that all technical data, qualities and functions are correctly stated and that it is possible to achieve them.

The supplier reports the results by using the Team Feasibility Commitment template (TFC-template) and by listing any concerns on the "Specification and Drawing Concern Sheet". Any open items from the "Specification and Drawing Concern Sheet" must be closed before the activity "Feasibility Study" is defined as completed.

This review is held with the appropriate participation from Autoliv and the supplier. The aim is to review and confirm all aspects in the contract between Autoliv and the supplier ( i e technical, commercial, logistic, quality , timing, results from the feasibility study etc ) The template "Contract Review" shall be used to document the agreements.

If the supplier is responsible for the design, date for release of final and complete product documentation e.g. bill of material, component/assembly drawings and specifications shall be defined and included in S-APQP.

If Autoliv is responsible for the design, a date for final documents (design freeze) and submission of documents shall be defined. The supplier shall proactively request missing documentation. If missing documentation compromises the project timeline the supplier shall inform the responsible buyer immediately in writing.

A plan shall be established for Prototypes including delivery dates, volumes, technical status (i e pre- serial parts), material planning and definition of tools and production equipment.

The material or components that shall be used must have APQP and PPAP activities planned. These must show that the materials are approved within the timeframe of the project and that used sub suppliers were selected according to defined supplier requirements. Even if the sub supplier is selected by Autoliv, the supplier is responsible for sub supplier APQP and performance.

DFMEA's shall be done according to the guidelines in the AIAG Failure Mode and Effects Analysis handbook.

If the supplier is not Design responsible, the DFMEA is completed by Autoliv. All pertinent information from the D-FMEA shall be communicated, understood and agreed upon between supplier and Autoliv to ensure full consistency between the D-FMEA and the P-FMEA. The supplier is responsible to assure that all necessary D-FMEA information is received in order to develop the P-FMEA. (See also item 15. P- FMEA below).

8 Special Characteristics

Strength

Hydrogen embrittlement

HardnessWhen hardness is a requirement, a minimum of three pieces per lot shall be tested.

9 Material and Substance Review

10 Reliability / Quality Prediction

If the supplier is responsible for the design, a D-FMEA shall be completed and submitted to Autoliv together with an action plan for acceptance by Autoliv.

D-FMEA shall be planned so that necessary actions can be implemented before the design phase of the project is closed. (Ref.: AS104 D-FMEA (Potential Failure Mode and Effects Analysis in Design))

The process to identify, control and verify Special Characteristics during development, PPAP and serial production shall be performed according to AS52. The CC/SC's shall be documented in the CC/SC list (AS 52 ). All identified CC/SC's carried through to all relevant documents (i.e. drawings , control plan, work instructions etc.)

If Autoliv is responsible for the design, the supplier shall receive information about CC/SC's from Autoliv. The supplier shall as a result from his P-FMEA process create a CC/SC list including the CC/SC's identified by Autoliv and by the supplier. The results from this process shall also be used to define those characteristics or process parameters which shall be controlled by SPC, 100% detection of defects or Poke-Yoke during serial production. The supplier shall submit results from his ongoing control and verification of CC/SC's as directed by the using Autoliv facility.

Further, if nothing else is specified, the below mentioned characteristics must be verified on finished components after all manufacturing process steps have been completed, prior to shipping of a manufacturing lot/batch to Autoliv. Method of testing to be agreed with Autoliv. The verification shall be included in the Control Plan.

When strength is a requirement, a minimum of three pieces per lot shall be tested, with a minimum of one per cavity. The failure strength and mode shall be noted on the certification/lab report.

When components are subject to hydrogen embrittlement, a minimum of five pieces per lot shall be tested.

The supplier shall, independent of whether Autoliv or the supplier makes the material selection, review the composition of each material. The materials shall be declared by the supplier through IMDS, according to the requirements and guidelines defined by the AS5, and approved by Autoliv. In the case of supplier designed or chosen materials, the supplier shall make sure the defined material conforms to the AS5. Materials, components and products containing substances classified as forbidden must not be used. If needed due to safety or other requirements, and no other alternatives exist the supplier shall notify Autoliv immediately, which will initiate a deviation process. Any deviation must ultimately be acknowledged by the vehicle manufacturer and approved centrally by Autoliv to become effective. (Ref. AS 5)

Specific requirements for semiconductors and electronic components

11 Software Validation Plan

12 Material / Performance Test Planning

13 Design Verification

14 Lot Traceability Plan

A flow chart describing the traceability and documentation procedure shall be established.(Ref.: AS 4)

15 Process Flow Diagram

16 Process-FMEA

If specified by Autoliv, the supplier shall evaluate design and process and define estimated quality level and reliability level .

It is required to calculate MTTF/FIT. Actions shall be established so defined requirements can be assured. This can be done by e.g. design evaluation, control plan evaluation, burn in test.

0 km failure rate shall be calculated in PPM. Calculations and action plans shall be reported and agreed by Autoliv.

If the product includes software developed by the supplier, validation plans shall be reported to and agreed by Autoliv.

Validation plans for all material tests and performance qualifications shall be established and resources provided (equipment, personnel and laboratory) Autoliv will specify the qualification testing.

If the supplier has the design responsibility, Design Validation shall be planned. Final product and process validation shall be realized by using serial status products.

The Process Flow Diagram shall include all processes from receiving, handling, manufacturing, final inspection, final product audit and dock-audit.

If the supplier is responsible for the design, the chosen design shall be tested and evaluated to assure that requirements and specifications are fulfilled. The verification shall be performed before the design phase is completed so corrections can be implemented in the design. Components and material shall be according to the drawing / specification

The supplier has to establish a plan to define how all raw material, components, sub-components, and production processes are traceable to the manufacturing lot/batch number or individual serial number. The requirements also apply as appropriate to any sub-contractor. (Lot/batch size is defined in ASM-Quality Requirements -"General")

The production process shall be planned and reported on a flow chart (including a lay-out) where all supplier, sub-supplier and transportation operations / processes are described. All operations shall be marked and correspond to P-FMEA and Control plan

The Process Flow Diagram shall include all processes from receiving, handling, manufacturing, final inspection, final product audit and dock-audit.

P-FMEA´s shall be done according to the guidelines in the AIAG Failure Mode and Effects Analysis handbook.

P-FMEA shall be carried out on the basis of the input from the D-FMEA , after a production layout and a process flow chart have been produced. The P-FMEA analysis performed by the supplier shall be reviewed with Autoliv to ensure that the D-FMEA and the P-FMEA are consistent including CC/SC's, failure effect , severity ratings, etc.

17 Control Plans

18 AS 2 Process Audit If requested by Autoliv, an AS 2 Process Audit specific to the project will be performed by Autoliv

19 Facilities and Process Equipment

20 Measuring and Test Equipment

21 Production Tooling Procurement

22 Work Instructions and Inspection Instructions

23 Training

24 Material Handling and Packaging Instructions

Knowledge of the product , production and inspection equipment capability shall always be considered. (Ref.: AS105)

The control plan shall be completed following the AIAG APQP/Control Plan manual and ISO/TS 16949. It shall be completed in three stages: Prototype, Pre-Launch (PV) and Production.

It shall be created on the basis of the P-FMEA and the Process Flow Diagram . All control operations shall be numbered and correspond with P-FMEA and Process Flow Diagram . CC/SC shall be marked and identified. Autoliv may require additional controls - i.e. inspections that must be adhered to.

The supplier shall review and evaluate the defined production site, available and planned additional production equipment, facilities and capacity. The activity includes specification, procurement and qualification of facilities and equipment to be used for manufacturing of the product.

The supplier shall review and evaluate the defined measuring and test equipment (available and planned ) and its capacity.

The activity includes specification, procurement and validation of measuring and test equipment to be used for manufacturing of the product.

A plan (incl. timing) shall be established for production tools and product specific control instruments. The plan must include timing regarding preparation of tooling drawings/specifications, manufacturing and qualification of the tooling.

Identified and defined tools and production equipment that shall be used for serial manufacturing shall be available at the time for the Production Trials and Product/Process Validation

Work, inspection, test and process instructions shall be defined describing manufacturing process procedures and inspection/testing procedures, responsibilities and actions in case of non conformities.

The supplier shall conduct a review of personnel to identify necessary competence and education . The result shall be presented in the form of a training plan/procedure, where the following has been identified: the required training, what is to be covered, who is doing the training, when it has to be done and confirmation that it has been carried out. All the required training and product knowledge shall be completed before the Run at Rate.

25 Maintenance Plan

26 Engineering Sample Approval (ESA)

27 Appearance Approval Report (AAR)

28 Sub supplier PPAP

29 Special processes

All required fixed parameters are to be defined as process instructions in the control plan.

30 First Production Trial Run and Corrective Actions

31 PPAP Production Trial Run and PPAP Package Preparation

32 Measurement System

The supplier shall complete an analysis of all handling and labeling which the product is subject to (from delivery of raw materials, through manufacturing to delivery to Autoliv) with the aim of ensuring that the materials/products are identified, handled, stored, packed and transported in such a manner that a change or deterioration is prevented. A plan for material handling shall include the product flow, replenishment system, and packaging (Ref.: ASM Logistics Requirements)

The supplier shall conduct and review a maintenance plan for production equipment. The documented plan shall be in accordance with requirements defined in ISO/TS 16949

If samples are evaluated by Autoliv e.g. form, fit or function, the approval and comments shall be documented. Samples shall be delivered to Autoliv for approval (Ref.: AIAG PPAP Manual - ESA form)

The supplier shall plan for evaluation of parts with visible surfaces, structure and colour. Samples and measuring results shall be reported on AAR and submitted to Autoliv for approval. ( Ref.: AIAG PPAP Manual -AAR template)

The supplier shall ensure that all components and materials to be used for serial manufacturing are PPAP approved or certified to raw material specification. Only approved material shall be used for manufacturing of PPAP parts and for product/process validation.

Special processes are processes where following inspection and testing cannot totally verify the results. Examples are: heat treatment, welding, surface treatment, gluing, soldering etc. Special processes shall be controlled and documented to assure the output meets specifications.

For heat treatment processes, acceptable results from an Autoliv heat treatment audit is required before PPAP can be approved. (Ref AS 069 " Heat treatment requirements")

The supplier shall schedule the First Production Trial Run to ensure adequate time for corrective actions before the PPAP Production Trial Run. Requirements and documentation shall be as defined in " Production Trial Run Standard ". (Reference ASM Product Life Cycle Step 7 "Production Trial Runs " and the " Production Trial Run Standard ".)

Date for PPAP Production Trial Run as well as the time required for PPAP preparation and submission shall be scheduled and included in S-APQP. (Ref.: Reference ASM Product Life Cycle Step 8 " PPAP and Run at Rate " and " Production Trial Run Standard ")

33 Initial Capability Studies

(Reference : "Production Trial Run Standard", AS 52, AIAG Manual "PPAP and "SPC" )

34 Product / Production Validation

35 PPAP Submission

36 Run at Rate Date for Run at Rate shall be scheduled and included in S-APQP. Autoliv shall always be informed about time for realisation so the opportunity is given to attend.

37 Start of Production (SOP)

38 Early Production Containment

39 Design Reviews

The supplier shall conduct an evaluation of all test and measuring methods that are planned for serial production. Gauge R&R values for measuring method, including operator, material and environmental variations shall be documented in the PPAP. Special attention shall be considered for verification of measuring method regarding CC / SC. (Reference: AIAG Manual "MSA Reference Manual")

The supplier shall perform an initial capability study (Ppk) to identify and verify the manufacturing process capability.

The supplier shall perform final tests and qualifications for product / process validation with products manufactured in the defined production process, under normal serial conditions and using PPAP approved or certified materials to ensure that product requirement, functions and specifications can be validated.

The supplier shall plan for preparation, submission and approval of PPAP documentation . In case submission date will be changed, supplier must inform Autoliv immediately using the S-APQP form. In case supplier will request an interim approval, the Interim Recovery Worksheet and any additional documents as defined by the using facility shall be submitted before PPAP. Reporting shall be done in accordance with the AIAG Production Part Approval Process manual ( Reference AIAG PPAP Manual and ASM - Quality Requirements -"PPAP")

(Reference : ASM Product Life Cycle Step 7 "Production Trial Runs and 8 " PPAP and Run at Rate " and " Production Trial Run Standard ")

Date for the supplier Start of Production shall be included in S-APQP and aligned with the Autoliv SOP date.

The content of the enhanced control and inspection activities shall be defined ,planned. and agreed with Autoliv. Before termination of the actual activities, the supplier must get an approval from Autoliv.

(Reference : AS 412 " Interim Inspection Plan "and ASM Product Life Cycle Step 10 "Performance Review / APQP Closure")

Supplier internal design review meeting schedule to be included. (Design review activities are defined in the AIAG manual "APQP".)

1. When you open this template, please confirm the Microsoft Excel messagebox with 'Activate macros'. Otherwise the template doesn't work correctly.

2. After successful confirmation of the macro activation you will be able to select a Autoliv location. The address and optional the phone/fax number will be placed at the left side of the footlines (only sheet General and Activity Planning). Double click at one of the listed Autoliv location or confirm with OK to prepare the footlines. Confirm with Cancel to ignore the footline definition.

3. At the bottom of the Excel application window is placed a specific toolbar, called 'S-APQP. This toolbar has the following three functionalities: a) Insert Line (Sheet General) b) Delete Line (Sheet General) c) Rename Actvity (only for users with the status Administrator; sheet Activity Planning)

4. Use the function 'Insert Line' to add an additional line at the section 'Project Team (Supplier)', 'Project Team (Autoliv)', 'Pre-Production delivery schedule', 'Review meetings Autoliv/Supplier' and 'Notes'. Therefore select one of the lines of the section above the new one should be inserted and confirm the function 'Insert Line'.

5. Use the function 'Delete Line' to delete a line of the section 'Project Team (Supplier)', 'Project Team (Autoliv)', 'Pre-Production delivery schedule', 'Review meetings Autoliv/Supplier' and 'Notes'. Therefore select the line of the section which has to be deleted and confirm the function 'Delete Line'. Minimum one line for each section is required.

6. Use the function 'Rename Activity' to change the name of the selected activity. Therefore select the activity which has to be changed and confirm the function 'Rename Activity'. Type in the Administrator password and confirm with OK. If the password is correct, please type in the new name of the activity an confirm with OK. Otherwise the process will be canceled.

7. The planning of the activities do not function for the past. For example: Current year is 2004, therefore no activities dated in 2003 are possible.

8. The strong yellow colored Activities are items of the critical path. For this activities only Administrators have the authority to make inputs and changes. Otherwise a wrong message will be shown.

9. Column Supplier Resp.: Please use the pulldown-list to select one of the listed team members. In some cases it's allowed to type in a name which isn't listed at the Supplier-Project-Team.

10. Columns 20%, 40%, 60%, 80% or 100%: Double click at the related status column (20%, 40%, 60%, 80%, 100%) of the Activity row to change the Ready Status. If the status is 20%, then double-click at 20% once again to set the Ready Status to 0%.

11. Column Status: Please use the pulldown-list to select one of the listed status Empty, Red, Yellow or Green. Use the first item 'Empty' to clear the status.

12. Please take care, that for the first time you have to type in the Planned-Start-Date and Planned-Due-Date and for the second time the Actual-Start-Date and Actual-Completion-Date. Otherwise a wrong message will be displayed.

13. Please use the date format 'YYYY-MM-DD' as titled in the header or all the other valid date formats, e.g. 'dd.mm.yy', 'dd.mm.yyyy', 'mm/dd/yy', ... Otherwise a wrong message will be displayed.

14. The Planned time frame will be highlighted as a bordered frame.

15. The Actual time frame will be highlighted with a blue colored background.

16. Maximum 4 calendar years are available for the project planning.

IMPORTANT FOR PRINTING:Please use the view 'Page Break Preview' from menu 'View' to set the horizontal and vertical page breaks manually. The blue continous drawed lines are manual page breaks, blue dashed lines are automatical page breaks. Move the page breaks to the place for optimal printout.Move the vertical page breaks that the whole calendar year is visible at the width of one page.

Please take care that you have to select any cell of the sheet General or Activity Planning after you have printed the document or if you go back from preview to normal view. This step is neccessary to reset the formats for the printout. Otherwise the document border could be faulty.

Documents

S-APQP