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7/17/2019 Apqp Forms
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Table of Contents
Appendix Reference Revision
1 Appendix_8 4/27/2007
2 Appendix_9 4/27/2007
3 Appendix_21 /9/200
4 Appendix_11 11/3/2008
! Appendix__1 11/21/2008
Appendix__1 3/12/2008
7 Appendix_1! 2/20/2008
8 "#$ Trainin% &ebsite 9//200!
9 "#$ Trainin% &ebsite 9//200!
10 "#$ Trainin% &ebsite 9//200!
A$"$ 'pen (ss)es
A$"$ Ti*in% $lan
A$"$ Contact +ist
A(A, A$"$ C-ec.lists
$ro%ra* Revie $aper lectronic
$ro%ra* Revie xpress All R)nRate #or*s RR for*s not incl)ded in t-e A$"$ for*s d)e to si5e6
elp-i $#A everit: Ran.in%s
elp-i $#A 'cc)rrence Ran.in%s
elp-i $#A etection Ran.in%s
Clic. on t-e title belo and :o) ill be lin.ed to t-e appropriateor.s-eet; To %et bac. to t-e Table of Contents< )se t-e
or.s-eet tab .e:s at t-e botto* or clic. on t-e bac. .e: at t-etop;
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APQP Open Issues)pplier/f%
+ocation= $art >)*bers6=
)pplier Contact= $ro%ra*s6=
elp-i " Contact= $art >a*e=
Responsibility Action Plan Progress
1.
2.
3.
4.
5.
6.
IssueNo.
IssueOrigin/Date
IssuesDescription and/or Sketch
Assigned
Date/StatusDate
Forecast
CopletionDate
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APQP Timing Plan
Supplier Duns: Part Number(s):
Supplier/Mfg Location: C+6
PPAP Date:
Supplier Contact: Description:
Supplier Telephone:
A!/S! Contact: (If applicable):
A!/S! Telephone: M"/Program:
Program !$ent Start %inish Status
Planne& Actual
16 )b*it Tea* #easibilit: Co**it*ent #or*
26 o)rce election b: elp-i $;'; (ss)ed
36 (nitiate A$"$ Activit:
46 evelop $rod)ct ")alit: Ti*in% $lan
!6 Co*plete $reli*inar: $rocess #lo ia%ra*
76 esi%n #A evelop or 'btain Cop:
86 esi%n Revie
106 Revie )bcontractor A$"$ tat)s
136 $rotot:pe ?)ilds
146 ,a%e Revies esi%n< ?)ild< RR
16 Revie ")alit: :ste*s$roced)res and 'perator &or. (nstr)ctions
176 Co*plete #inal $rod)ction $rocess #lo C-art
Tool Supplier
Planne&**/dd/::6
Actual**/dd/::6
6 Co*plete $reli*inar: +istin% of pecial $rod)ct and $rocess C-aracteristics
96 Revie pecifications=n%ineerin%< aterial< rain%
116 Co*plete #acilit: +a:o)t
126 Co*plete ac-iner: @)ip*ent < Toolin% esi%n ?)ild
1!6 )b*it Tea* #easibilit: Co**it*ent #or* esi%n
186 Co*plete $rocess #A
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Supplier ualit' APP Proect Contact List
Supplier Co&e Manufacturing A&&ress
Supplier Name
Contacts Name an& Title Mailing A&&ress an& !Mail A&&ress Contact Numbers
ales Contact
$rod)ct n%ineer
")alit: Resident
$ro%ra* ana%er
in ales 'ffice
$ro%ra* ana%er
in an)fact)rin% #acilit:
A$"$ Contact
")alit: ana%er
")alit: n%ineer
1st -ift Contact
2nd -ift Contact
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A!" D#SI$N F%#A C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
"
0 Does the DF%#A identi1y Special Characteristics2
3
4
5
6
7
"8
Re*ision Date9
Pg. " o1 "
Prepared :y9
;as the DF%#A prepared using the Chrysler,
Ford and General Motors Potential Failure Modeand Effects Analysis FMEA! re1erence anual<and applicable custoer speci1ic re-uireents2
&a*e historical capaign and =arranty data beenre*ie=ed2
&a*e best practices and lessons learned 1ro
siilar part DF%#As been considered2
&a*e pass!through characteristics >glossary? beenidenti1ied and re*ie=ed =ith a11ected suppliers 1or
F%#A alignent and appropriate controls in thesupply base2
&a*e special characteristics designated by the
custoer or organi@ation been re*ie=ed =ith
a11ected suppliers to assure F%#A alignent2
&a*e design characteristics that a11ect high riskpriority 1ailure odes been identi1ied2
&a*e appropriate correcti*e actions been assignedto high risk priority nubers2
&a*e appropriate correcti*e actions been assignedto high se*erity nubers2
&a*e risk priorities been re*ised =hen correcti*e
actions ha*e been copleted and *eri1ied2
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A! D#SI$N INFOR%A)ION C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
A. $eneral
" Does the design re-uire9
a - New materials?
b - !e"ial tooli#g?
" - New te"$#ology or !ro"ess?
&as Design o1 #perients been considered2
0 Is there a plan 1or prototypes in place2
3 &as a DF%#A been copleted2
4
5
6 &as the Design Beri1ication Plan been considered2
7
"8
"" &a*e Special Characteristics been selected2
" Is bill o1 aterial coplete2
" Are Special Characteristics properly docuented2
Re*ision Date9
Pg. " o1
&as assebly build *ariation analysis beenconsidered2
&as a DF%A >Design 1or %anu1acturability andAssebly? been copleted2
&a*e ser*ice and aintenance issues beenconsidered2
I1 yes< =as it copleted by a cross 1unctional
tea2
Are all speci1ied tests< ethods< e-uipent and
acceptance criteria clearly de1ined andunderstood2
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A! D#SI$N INFOR%A)ION C&#C'(IS) ! CON)IN#D
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
:. #ngineering Dra=ings
"0
"3
"4
"5
"6
C. #ngineering Per1orance Speci1ications
"7 &a*e special characteristics been identi1ied2
8
"
;ill all product testing be done in!house2
I1 not< is it done by an appro*ed supplier2
0
3
Re*ision Date9
Pg. o1
Are re1erence diensions identi1ied to inii@einspection layout tie2
Are su11icient control points and datu sur1acesidenti1ied to design 1unctional gages2
Are tolerances copatible =ith acceptedanu1acturing standards2
Can eisting and a*ailable inspection technology
easure all design re-uireents2
Is the custoer designated engineering changeanageent process used to anage engineeringchanges2
Are test paraeters su11icient to address re-uireduse conditions< i.e.< production *alidation and enduse2
&a*e parts anu1actured at iniu andaiu speci1ications been tested as re-uired2
Is the speci1ied in!process per1orance testsapling si@e and/or 1re-uency consistent =ithanu1acturing *olues2
&as custoer appro*al been obtained< e.g.< 1or
testing and docuentation< as re-uired2
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A! D#SI$N INFOR%A)ION C&#C'(IS) ! CON)IN#D
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
D. %aterial Speci1ication
4 Are special aterial characteristics identi1ied2
5
6
7
8
I1 so<
a - %ill "$ara"teristi"s be "$e"&e' i#-$o(se?
b - )* "$e"&e' i#-$o(se+ is test e,(i!me#t aailable?
"
" ;ill outside laboratories be used2
a
a - a#'li#g+ i#"l('i#g e#iro#me#tal as!e"ts?
b - torage+ i#"l('i#g e#iro#me#tal as!e"ts?
"
'
Re*ision Date9
;here the organi@ation is design responsible< arespeci1ied aterials< heat treat and sur1acetreatents copatible =ith the durabilityre-uireents in the identi1ied en*ironent2
;here re-uired< are the aterial suppliers on the
custoer appro*ed list2&as the organi@ation de*eloped and ipleenteda process to control incoing aterial -uality2
&a*e aterial characteristics re-uiring inspectionbeen identi1ied2
- )* "$e"&e' i#-$o(se+ are "om!ete#t !eo!le
aailable to ass(re a""(rate testi#g?
- /oes t$e orga#iatio# $ae a !ro"ess i# !la"e toass(re laboratory "om!ete#"y s("$ as a""re'itatio#?NO)#9 Copetency needs to be assured<
regardless o1 the organi@ations relationship =iththe laboratory.
&a*e the 1ollo=ing aterial re-uireents beenconsidered9
- ae t$e materialss(bsta#"e "om!ositio# bee#re!orte' i# a""or'a#"e wit$ "(stomer re,(ireme#tse.g.+ )/?
- ae !olymeri" !arts bee# i'e#ti*ie'mar&e' !er"(stomer re,(ireme#ts?
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A! N#; #+IP%#N)< )OO(IN$ AND )#S) #+IP%#N) C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
" Does the design re-uire9
a - New materials?
b - (i"& "$a#ge?
" - ol(me *l("t(atio#s?
' - ista&e !roo*i#g?
a - New e,(i!me#t?
b - New tooli#g?
" - New test e,(i!me#t i#"l('i#g "$e"&i#g ai's?
a - New e,(i!me#t?
b - New tooli#g?
" - New test e,(i!me#t i#"l('i#g "$e"&i#g ai's?
0
3
4
Re*ision Date9
Pg. " o1
&a*e lists been prepared identi1ying9 >Include allsuppliers?
&a*e acceptance criteria been agreed upon 1or9>Include all suppliers?
;ill a preliinary capability study be conducted
at the tooling and/or e-uipent anu1acturer2
&as test e-uipent 1easibility and accuracy been
established2
Is a pre*entati*e aintenance plan coplete 1ore-uipent and tooling2
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A! N#; #+IP%#N)< )OO(IN$ AND )#S) #+IP%#N) C&#C'(IS) ! CON)IN#D
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
5
6
7
"8
""
"
"
"0
Re*ision Date9
Pg. o1
Prepared :y9
Are setup instructions 1or ne= e-uipent and
tooling coplete and understandable2
;ill capable gages be a*ailable to run preliinary
process capability studies at the e-uipentsuppliers 1acility2
;ill preliinary process capability studies be runat the processing plant2
&a*e process characteristics that a11ect special
product characteristics been identi1ied2
;ere special product characteristics used indeterining acceptance criteria2
Does the anu1acturing e-uipent ha*e su11icient
capacity to handle 1orecasted production andser*ice *olues2
Is testing capacity su11icient to pro*ide ade-uate
testing2
&as the easureent e-uipent been *eri1ied and
docuented sho=ing -uali1ication 1or the re-uiredscope o1 easureent and testing2
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A!0 PRODC)/PROC#SS +A(I), C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
"
0
3 Are there su11icient personnel identi1ied to co*er9
a - o#trol !la# re,(ireme#ts?
b - ayo(t i#s!e"tio#?
" - #gi#eeri#g !er*orma#"e testi#g?
' - Problem rea"tio# a#' resol(tio# a#alysis?
4 Is there a docuented training progra that9
a - )#"l('es all em!loyees?
b - ists w$ose bee# trai#e'?
" - Proi'es a trai#i#g s"$e'(le?
5 &as training been copleted 1or9
a - tatisti"al Pro"ess o#trol?
b - a!ability st('ies?
" - Problem soli#g?
' - ista&e !roo*i#g?
e - ea"tio# !la#s?
* - ;t$er to!i"s as i'e#ti*ie'?
6
Re*ision Date9
Pg. " o1 0
Is custoer assistance or appro*al re-uired 1or the
de*elopent o1 the control plan2
&as the organi@ation identi1ied =ho =ill be the-uality liaison =ith the custoer2
&as the organi@ation identi1ied =ho =ill be the-uality liaison =ith its suppliers2
&as the -uality anageent syste been re*ie=ed
and appro*ed per custoer speci1ic re-uireents2
Is each operation pro*ided =ith processinstructions that are keyed to the control plan2
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A!0 PRODC)/PROC#SS +A(I), C&#C'(IS) ! CON)IN#D
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
7
"8
""
" Do inspection instructions include9
a
b - <est *re,(e#"ies?
" - am!le sies?
' - ea"tio# !la#s?
e - /o"(me#tatio# re,(ireme#ts?
" Are *isual aids9
a - =!!ro!riate+ easily (#'erstoo' a#' legible?
b - =ailable?
" - =""essible?' - =!!roe'?
e - /ate' a#' "(rre#t?
"0
"3
"4
a
Re*ision Date9
Pg. o1 0
Are standard operator instructions accessible at
each =ork station2
Do operator instructions include pictures and
diagras2
;ere operator/tea leaders in*ol*ed in de*elopingstandard operator instructions2
- asily (#'erstoo' e#gi#eeri#g !er*orma#"e
s!e"i*i"atio#s?
Is there a procedure to ipleent< aintain< andestablish reaction plans< 1or issues such as out o1
control conditions based on statistical processcontrol2
Is there an identi1ied proble sol*ing process that
includes root cause analysis2
Are the latest dra=ings and speci1icationsa*ailable 1or the operator< in particular at thepoints o1 the inspection2
- ae e#gi#eeri#g tests 'ime#sio#al+ material+a!!eara#"e+ a#' !er*orma#"e bee# "om!lete' a#''o"(me#te' as re,(ire' i# a""or'a#"e wit$ "(stomerre,(ireme#ts?
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A!0 PRODC)/PROC#SS +A(I), C&#C'(IS) ! CON)IN#D
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
"5
"6
a - o#itori#g a#' meas(reme#t 'ei"es?
b - >age i#str("tio#s?
" - e*ere#"e sam!les?' - )#s!e"tio# logs?
"7
8
a - om!lete'?
b - =""e!te'?
"
a - $ara"teristi"s to be i#s!e"te'? b - re,(e#"y o* i#s!e"tio#?
" - am!le sie?
' - /esig#ate' lo"atio# *or a!!roe' !ro'("t?
e - /is!ositio# o* #o#"o#*ormi#g !ro'("ts?
0
Re*ision Date9
Are the current 1ors/logs a*ailable 1or
appropriate personnel to record inspection results2
Are the 1ollo=ing a*ailable and placed at the
appropriate points o1 the operation2
&a*e pro*isions been ade to certi1y and calibrategages and test e-uipent at a de1ined 1re-uency
that is appropriate2
&a*e re-uired easureent syste capability
studies been9
&a*e initial process capability studies beenconducted per custoer re-uireents2
Are layout inspection e-uipent and 1acilities
ade-uate to pro*ide initial and ongoing layout o1all details and coponents in accordance =ithcustoer re-uireents2
Is there a docuented procedure 1or controllingincoing aterial that ay include< 1or eaple<the 1ollo=ing ites9
&a*e saple production parts been pro*ided percustoer re-uireents2
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A!0 PRODC)/PROC#SS +A(I), C&#C'(IS) ! CON)IN#D
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
3
4
5
6
7 Is there an appropriate lot traceability procedure2
8
"
Re*ision Date9Pg. 0 o1 0
Prepared :y9
Is there a procedure to identi1y< segregate< and
control noncon1oring products to pre*entshipent2
Are re=ork/repair procedures a*ailable to assurecon1oring product2
Is there a procedure to re-uali1yrepaired/re=orked aterial2
&as a aster saple< i1 re-uired< been retained as
part o1 the part appro*al process2
Are periodic audits o1 outgoing products plannedand ipleented2
Are periodic assessents o1 the -uality systeplanned and ipleented2
&as the custoer appro*ed the packaging and thepackaging speci1ication2
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A!3 F(OOR P(AN C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
"
0
3 Are process and inspection areas9
a - ;* a'e,(ate sie?
b - Pro!erly lig$te'?
4
5 Are there ade-uate9
a - tagi#g areas?
b - )m!o(#' areas?
6
7
"8
""
"
Re*ision Date9
Pg. " o1 "
Prepared :y9
&a*e lean concepts been applied in considering
aterial 1lo=2
Does the 1loor plan identi1y all re-uired process
and inspection points2
&a*e clearly arked areas 1or all aterial< tools<and e-uipent at each operation been considered2
&as su11icient space been allocated 1or alle-uipent2
Do inspection areas contain necessary e-uipentand record storage2
Are inspection points located to pre*ent shipento1 noncon1oring products2
Are there controls 1or each process to eliinatecontaination or inappropriate iing o1
Is aterial protected 1ro o*erhead or airhandling systes containation2
&a*e 1acilities been pro*ided 1or 1inal product
audit2Are 1acilities ade-uate to control o*eent o1noncon1oring incoing aterial2
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A!4 PROC#SS F(O; C&AR) C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
"
0
3
4
5
Re*ision Date9
Pg. " o1 "
Prepared :y9
Does the 1loor chart illustrate the entire process
1ro recei*ing through shipping< including outsideprocesses and ser*ices2
In the de*elopent o1 the process 1lo= chart< =asthe DF%#A used< i1 a*ailable< to identi1y speci1ic
characteristics that ay be critical2
Is the 1lo= chart keyed to product and processchecks in the control plan and PF%#A2
Does the 1lo= chart describe ho= the product =illo*e< i.e.< roller con*eyor< slide containers< etc.2
&as the pull syste/optii@ation been considered1or this process2
&a*e pro*isions been ade to identi1y and inspect
re=orked product be1ore being used2
Are aterial controls 1or o*eent and staging o1
product including appropriate identi1icationproperly de1ined and ipleented2 )he controlsshould address incoing supplier product as =ell
as subcontracted processes2
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A!5 PROC#SS F%#A C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person Due
Responsible Date
"
0 ;ere siilar part/process F%#As considered2
3
4
5
6
7
"8
""
Re*ision Date9
Pg. " o1 "
Prepared :y9
;as the Process F%#A prepared by a cross1unctional tea2 &as the tea taken into accountall custoer speci1ic re-uireents< includingF%#A ethodologies as sho=n in the current
edition o1 F%#A2
&a*e all operations including subcontracted< oroutsourced processes and ser*ices been
considered2
&a*e all operations a11ecting custoerre-uireents including 1it< 1unction< durability<
go*ernental regulations and sa1ety beenidenti1ied and listed se-uentially2
&a*e historical capaign and =arranty data beenre*ie=ed and used in the analysis2
&a*e you applied the appropriate controls to
address all o1 the identi1ied 1ailure odes2
;ere se*erity< detection and occurrence re*ised=hen correcti*e action =as copleted2
Do the e11ects consider the custoer in ters o1 thesubse-uent operation< assebly< and product2
;ere custoer plant probles used as an aid inde*eloping PF%#A2
&a*e the causes been described in ters o1soething that can be corrected or controlled2
&a*e pro*isions been ade to control the cause o1
the 1ailure ode prior to subse-uent or the netoperation2
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A!6 CON)RO( P(AN C&#C'(IS)
Custoer or Internal Part No. Re*ision (e*el
+uestion ,es No N/A Coent/Action Re-uired Person DueResponsible Date
"
0
3
4
5
6
7
"8
""
"
Re*ision Date9
Pg. " o1 "
Prepared :y9
;as the control plan de*eloped according to the
ethodology described in Chapter 4 o1 this AP+Panual2
&a*e all the controls identi1ied in the PF%#A beenincluded in the control plan2
Are all special product/process characteristicsincluded in the control plan2
;ere DF%#A and PF%#A used to prepare the
control plan2
Are aterial speci1ications re-uiring inspectionidenti1ied2
Does the control plan address incoing>aterial/coponents? throughprocessing/assebly including packaging2
Are engineering per1orance testing and
diensional re-uireents identi1ied2
Are gages and test e-uipent a*ailable as re-uired
by the control plan2
I1 re-uired< has the custoer appro*ed the control
plan2
Are the gage ethodology and copatibility
appropriate to eet custoer re-uireents2
&a*e easureent systes analysis been
copleted in accordance =ith custoerre-uireents2
Are saple si@es based upon industry standards<statistical sapling plan tables< or other statisticalprocess control ethods or techni-ues2
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Meeting Plan Chec+list
A! ,nput
tili5e $ro%ra* Revie #or* or
tli5e xpress $ro%ra* Revie #or*
$$A$ Re@)ire*ents
RR Ti*in% and Re@)ire*ents
elp-iBs C)sto*er pecific Re@)ire*ents
(ntrod)ction/(nstr)ctions to all elp-i )pplier &ebsites;
!ngineering ,nput+atest part prints and specifications
$ro%ra* Ti*in% / Critical C-aracteristics
Tec-nical oc)*ents incl)din% s)bco*ponent drain%s;
$ro%ra* (nfor*ation s)c- as esti*ated ann)al )sa%e< $$A$ dates< '$ dates< etc;
$ilot and $rotot:pe re@)ire*ents and ti*in%;
e:/Critical c-aracteristics for $$A$
*u'er ,nput (from -uote)$ac.a%in% plan
")oted Tool Capacit:
sti*ated Ann)al Dol)*e
Supplier ,nput)pplier corecard< be prepared to disc)ss
pdated s)pplier infor*ation )pplier $rofile6 incl)din% contact list;
$ro%ra* Ti*in% incl)din% toolin%< $$A$< RR
)pplier iss)es/concerns ca)sed b: elp-i elp-i;)pplier iss)es/concerns not associated it- elp-i;
")estions/concerns needin% to be addressed b: elp-i
#ther Potential Supplier ,nput(nfor*ation on t-e *an)fact)rin% facilit: +ocation< Capacit:< etc;6
$reli*inar: $rocess #lo ia%ra* $#6
$reli*inar: Control $lan
$reli*inar: Ti*in% C-arts
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D!LP., P#0AM !1,!2 S3MMA"
ate of Revie= Ne4
)pplier = eter*
)pplier )ns= )bTier )pplier GG=
)pplier/f% +ocation=
$ART >?R CR($T('> '+ +$H( $+AT#'R H(,H D'+
FAR TART '# C>AR('
$R'CT('> De-icles61
2
3
4
!
C.!C5 ,% ,N ATT!NDANC!
+$H( C'>TACT
T(T+ >A $H'> A(+ A"
"
?FR
$R',RA ,R
$$A$ C''R(>AT'R
C'$'>>T >,(>R
$R'CT >,(>R
R$'> TA
$$+(R C'>TACT
>A $H'> A(+$R(>T
"A+(TF A>A,R
F C'>TACT
$$A$ C'>TACT
"A+(TF C'>TACT
R>RAT C'>TACT
+in. to A(A, &eb ite
GG +ist if s)btier s)pplier contrib)tes *ore t-an !0I of *an)fact)rin%< controls a*a: be re@)ired for t-is s)pplier; Reference Tea* #easibilit: doc)*ent on R#"
Critical process s)btiers for -eat treatin%< coatin% and platin% *)st co*pl: it- to co*plete t-e assess*ents; ee ection
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)pplier
C etails Responsibilit:
7 $latfor*
8 odel Fear
9 elp-i sti*ated Ann)al Dol)*e
)pplier $$A$ )e ate
; elp-i '$
< elp-i an)fact)rin% ite
= )pplier ")oted Tool Capacit: ! da:s6
D etails Responsibilit:
7 $rotot:pe re@)ire*ents;
8 $re$rod)ction Re@)ire*ents
9 't-er $rod)ct Re@)ire*ents
! etails Responsibilit:
7 )pplier Toolin% Co*pletion ates
8 Toolin% )pplier >a*e if different6
% etails Responsibilit:
7 evelop*ent and Approval of ,a%e esi%n $lan
8 ,a%e val)ation incl)din% eas)re*ent :ste* Anal:sis A6
9 ,a%in% Co*pletion ates
0 etails Responsibilit:
767
Note: Shipping Container P+g > Labeling re-uirements )ppliers *)stco*pl: it- re@)ire*ents; Co**)nicate to s)ppliers t-at t-e: s-o)ld contactt-eir elp-i $C+ rep; if t-e: -ave @)estions or need assistance; (nfor*ationcan also be fo)nd on t-e elp-i
Program ,nformation+ist infor*ation re@)ired belo
#orecastCo*pletion
ate
Pro&uct e-uirements > TimingRecord t-e folloin% if applicable;
#orecastCo*pletion
ate
Supplier Tooling e-uirementsevelop a pro%ra* revie for t-e toolin% s)pplier on criticalco*ponents;
#orecastCo*pletionate
Supplier 0age e$ie4)t)al A%ree*ent on %a%e concept proposal;Certif: ,a%e to prod)ct desi%n record;
#orecastCo*pletion
ate
Pro&uct Measurement PlanHave acceptable *eas)re*ent *et-ods been confir*ed andcorrelatedJ
#orecastCo*pletion
ate
Has elp-i received t-e s)pplierMs plan for di*ensional la:o)t and*eas)re*ent of t-e co*ponentJ -o)ld incl)de t-e *eas)re*ent*et-ods< la:o)t< dat)*s< tools< e@)ip*ent and fixt)res if applicable66
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9
;
<
? etails Responsibilit:
7
8 Has t-e elp-i $T revieed t-e #AJ
9
5 A)dit Co*pletion ate Responsibilit:
7 C"( 9 Heat Treat*ent assess*ent is re@)ired=
8 C"( 11 $latin% assess*ent is re@)ired=
9 C"( 12 Coatin% assess*ent is re@)ired=
L etails Responsibilit:
7
8
9
;
M etails Responsibilit:
7
eas)re*ent @)ip*ent N3 et-odolo%:
eas)re*ent @)ip*ent N4 et-odolo%:
eas)re*ent @)ip*ent N!
et-odolo%:
eas)re*ent @)ip*ent N et-odolo%:
Design esponsible Suppliers+ist all iss)es/re@)ire*ents if t-e s)pplier is desi%n responsible;
#orecastCo*pletion
ate
&as a esi%n #ail)re odes ffects Anal:sis #A6 initiated b:t-e s)pplierJ
Are #A open ite*s addressed on an action plan andco**)nicated to elp-iBs $TJ
Special Process#or )ppliers and )b)ppliers it- C"(9< 11 or 12 re@)ire*ents<co*plete t-e folloin%=
#orecastCo*pletion
ate
PPAP 0ui&elinesT-e lin. belo ill ta.e :o) to t-e elp-i $$+(R $$A$?(('> CHC+(T; tili5e t-e C-ec.list for $$A$disc)ssions; +ist potential iss)es belo for trac.in% p)rposes;
#orecastCo*pletion
ate
Lin+ to S3PPL,! PPAP S3*M,SS,#N !3,!M!NTSC.!C5L,ST(3se attache& lin+ or 4or+sheet $ersion pro$i&e&6) -ttps=//delp-i;portal;covisint;co*/c/doc)*ent_librar:/%et_fileJfolder(dK114313na*eK+#10
%irst Time ualit' (%T) ,mpro$ement Process#orecast
Co*pletionate
#T" (*prove*ent $rocess (nitiationRevie elp-iBs #T" proced)re and trainin% presentations asre@)ired;
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# etails Responsibilit:
7 Capabilit' to access/up&ate the follo4ing:
767 )pplier $rofiles isc)ss Red/Fello/,reen stat)s6
768 )pplier )%%estions $ro%ra* $/CR6
769 )pplier corecard pdated cop: if c)rrent s)pplier6
76 $roble* olver
76; C)sto*er pecific Re@)ire*ents / ")alit: xpectations
76< Additional #or*s $roced)res available on t-e ebsite
8
867 (nitial electronic $$A$ s)b*issions
868 $/CR re@)ired $$A$ s)b*issions
2!*S,T! ,N%#MAT,#Neter*ine t-e s)ppliers access and or.in% .noled%e of eac-elp-i database belo;
#orecastCo*pletion
ate
egistere& to the Delphi Supplier 2ebsiteMainl' use& for electronic PPAP submissions
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$a%e 24 +ast Revised= 8/22/07
The follo4ing instructions are inten&e& to help the A!/S! in performing the Program e$ie46 Ta+e a moment to re$ie4 the
,nstructions6 The intent of the program re$ie4 is to engage the supplier in con$ersations about $arious aspects of the current
program/parts an& &etermine areas of concern that 4ill nee& further action6
The form is protecte&/loc+e& so that users can tab through fiel&s6 To allo4 attachments (such as program rosters) an&/or
This 4ill allo4 each user to customie the program re$ie4 to fit their nee&s 4hile continuing to use a common form an& process6
2e 4ill start the instructions 4ith &efinitions an& acron'ms:
5PC 5e' Pro&uct Characteristics
ost i*portant prod)ct feat)res or *aterial properties for *eetin% c)sto*er re@)ire*ents;
T-e to .inds of $Cs are 16 safet: and co*pliance< and 26 fit and f)nction; $Cs *a: be attrib)tes present or not6;
(t is re@)ired to tar%et variable $Cs at no*inal and red)ce variation contin)o)sl: beca)se t-ese c-aracteristics are opti*i5ed at t-e no*inal
specification and -ave a loss f)nction associated it- deviatin% fro* no*inal;
5CC 5e' Process Control Characteristic
ost i*portant process c-aracteristics t-at -ave a direct effect on t-e $Cs;
)ppliers *a: desi%nate additional process c-aracteristics as CCs;
C, ualit' / Customer ,nterface
A feat)re or propert: of a prod)ct t-at is contacted directl: b: t-e c)sto*er and -as an i**ediate i*pact on t-eir satisfaction
if not it-in li*its; 'r< a c-aracteristic t-at does not *eet t-e $C criteria< b)t is dee*ed critical to t-e final prod)ct or its *an)fact)rabilit:;
CC ualit' Control Characteristic
ost i*portant process c-aracteristics t-at -ave a direct effect on t-e "C(Bs; )ppliers *a: desi%nate additional process c-aracteristics as "C(Bs;
PPAP Pro&uct Part appro$al process6
PassThrough Characteristic
(s a c-aracteristic/feat)re -ere an ano*ol: onl: declares itself )nder certain conditions s)c- as environ*ental sti*)lation and cannot be tested
in elp-iBs operations i;e; soft tie rods< stepper *otor it- step loss and steerin% -ose it- incorrect r)bber co*ponent;
an&/or a&&itional information into an' open fiel& 4ithin the formB the form can be unprotecte&6 The pass4or& is unloc+6
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$a%e 2! +ast Revised= 8/22/07
T-e first part of t-e $ro%ra* Revie is an infor*ational list )sed b: elp-i and t-e )pplier for better co**)nication;
#ill in t-e folloin% infor*ation as t-oro)%-l: as possible=
ate of Revie
)pplier incl)de bot- t-e facilit: na*e and parent na*e -ere applicable
)pplier )ns Code t-is is in reference to t-e *an)fact)rin% site prod)cin% t-e prod)ct;
)pplier/f% +ocation
$art >)*bers
$$A$ ate
escription
$latfor*
odel Fear
'$ ate
)pplier Contacts= +ist .e: s)pplier contacts
e: Contact
$$A$ Contact
")alit: ContactR)nRate Contact
elp-i Contacts +ist .e: elp-i contacts
A"
"
?):er
$ro%ra* ana%er
$$A$ Coordinator
Co*ponent n%ineer
$rod)ct n%ineer
Response Tea*Ne4 is+ Le$el of Pro&uct 'nce t-e revie -as been co*pleted< eval)ate t-e pro%ra* ris. based on :o)r findin%s;
ections A t-ro)%- are )sed to trac. t-e pro%ress of t-e s)pplier t-ro)%- vario)s aspects of b)ildin% a ne prod)ct; ac- section
foc)ses on a specific area and is as co*pre-ensive as possible;
T-e for*attin% for t-ese t-ree colors -as been a)to*ated; ,o to t-e cell :o) ant to c-an%e< t-en -it t-e folloin% .e:=
for red )se OCtrlrO for :ello )se OCtrl:O for %reen )s OCtrl%O t-is codin% ill also s-o )p in blac./-ite copies it- patterns for eac- color;
;
T-e col)*ns represented in eac- section are )sed to pro*ote co**)nication beteen elp-i and t-e s)pplier; (t also deter*ines responsibilit:<
forecasts co*pletion dates< action plans< act)al co*pletion dates and pro%ress; ac- bloc. is expandable to add infor*ation as necessar:;
T-e folloin% %ives an explanation of eac- section=
ection A $rod)ct Application Revie -o t-e prod)ct ill be )sed at elp-i and t-e c)sto*er< etc;
ection ? esi%n Revie Revie prints/specs/ "C(/$C< and passt-ro)%- c-aracteristic/feat)re< pac.a%in% and labelin% re@)ire*ents;
T-e first col)*ns ill be )sed to color code eac- line ite*; ,reen indicates co*pleted< Fello indicates 'pen it- recover: plan<Red indicates t-e s)ppliers process ill not *eet elp-i re@)ire*ents;
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$a%e 2 +ast Revised= 8/22/07
ection C $ro%ra* (nfor*ation Revie it- s)pplier so t-e: )nderstand t-e final prod)ct and itBs re@)ire*ents;
ection $rod)ct Re@)ire*ents Ti*in% N of parts re@)ired< t:pe of prod)ct saleable vs nonsaleable6 to be recorded;
ection )pplier Toolin% Re@)ire*ents Toolin% co*pletion and possible roadbloc.s s-o)ld be disc)ssed;
ection # )pplier ,a%e Revie val)ate and approve %a%e desi%ns;
ection , $rod)ct eas)re*ent $lan Consider t-e *eas)re*ent re@Bt and tec-ni@)es t-at ill be )sed for di*ensional la:o)t on t-e co*ponent prior to ppap;
ection H Capabilit: Assess*ent ,)idelines eter*ine based on t-e print re@)ire*ents< c)sto*er re@)ire*ents; etail t-is section ell;
ection ( eas)re*ent :ste*s Anal:sis ,)idelines ?ased on t-e ite* listed in section H< detail e@)ip*ent and *et-odolo%ies t-at ill be )sed;ection P esi%n Responsible )ppliers (f :o)r s)pplier is responsible for t-e desi%n< t-is section s-o)ld be disc)ssed;
ection pecial $rocess vidence of confor*ance to re@)ired C"( assess*ent re@)ired -ere;
ection + $$A$ ,)idelines H:perlin. to elp-iBs $$A$ c-ec.list
ection #irst Ti*e ")alit: #T"6 (*prove*ent $rocess Trainin% and or evidence of confor*ance is revieed in t-is section;
ection > R)nRate Re@)ire*ents H:perlin. to elp-iBs RR plan
ection ' &ebsite (nfor*ation +ists all ebsites and pro%ra*s t-e s)pplier ill need in or.in% it- elp-i;
"E "P R i
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$a%e 27 +ast Revised= 8/22/07
"Express" Program Review
Part Number:
Delphi ,nformation (%rom oster Database > e-uest for Sourcing): %amil' Parent Part No6 (if an'):
1 elp-i tart 'f $rod)ction ate Pro&6 Mfg6 Loc6:
2 Fear=
3 Ann)al sa%e=
4 $ea. &ee.l: sa%e=
! T:pe of ?)ild=
$arts re@)ired ate=
7 ")antit:=
8 $+
9 ?)ild -en $$A$ is re@)ired=
10 )pplier $$A$ )e ate
11 $$A$ +evel Re@)ired 3
12 Co**ents
13 )pplier #irst $arts $ro*ise ate
14 sti*ated $$A$ pac.a%e deliver:
1! )pplier ")oted ! a: Capacit:
vs; $ea. sa%e in @)estion N46
1 T-e s)pplier is responsible to re%ister and )se t-e elp-i )pplier &ebsites and *)st be capable to )pdate and access t-e folloin%=
)pplier $rofiles
)pplier )%%estion $ro%ra* $ / CR6
$roble* olver
C)sto*er pecific Re@)ire*ents/ ")alit: xpectations
( s:ste* reportable C-e*icals6
ection A= )pplier $ro%ra* Revie
1olume,nformation
%orecaste&*uil&s
ection ?= )pplier Co**it*ents )pplier co*plete6:
17 T-e )pplier a%rees to and )nderstands t-e folloin%=
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$a%e 28 +ast Revised= 8/22/07
pp % %
1; T-e onl: a)t-ori5ation to i*ple*ent elp-i en%ineerin% c-an%es incl)din% *ar.ed )p prints6 *)st be iss)ed b: t-e elp-i ?):er;
prior ritten approval of elp-i Corporation;
A%reed b:=
Authorie& representati$e Date
18 )pplier Co**ents/ Concerns=
19 (s $art Co**odit: xe*ptJ F/> +etter +ocation=
20 xe*ption Calc; -i%-est N 1! / N 46 if less t-an 40I< *a: exe*pt R)n Rate6
21 Approvin% )pplier ")alit: ana%er ate=
22 Co**ents=
#or e*icond)ctors R)n at Rate is exe*pt; To ens)re co**it*ents are *et a CA$AC(TF TF is re@)ired;
"Express" Program Review
2; >o c-an%e< of an: .ind< s-all be *ade in *aterial content< processin% *et-ods< testin% *et-ods< or location of *an)fact)re it-o)t t-e
ection C= R)n Rate =
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$$ xpress #or*
(nstr)ctionsP,NT ,N P#TA,T M#D!
l
l
l
l
l
$$ xpress for*s s-o)ld be filled in< trans*itted< and stored electronicall:; #or T-e: s-o)ldbe stored in T=Q$RCHA(>,Q$+_DQA"QR(
A>TQ$RQOC''(TFOQO$$+(R >AOQO$ART NO$lease )se t-e part n)*ber as t-e first part of t-e filena*e and p)t a 5ero in front of 9 *illion partn)*bers to ac-ieve 8 di%its and proper sort order b: &indos xplorer6;
T-e tab .e: can be )sed to *ove to t-e next available field in t-e for* to enter data; i*ilarl:<s-ift_tab ill *ove to t-e previo)s available field;
#or fillin% in t-e SPDP !press for*=Section A: Dol)*e (nfor*ation and c-ed)led ?)ilds lines 1 to 106 s-o)ld be filled in b: t-e Pro&uct !ngineer or t-e Program Team Lea&er ; +ine 11 ill be filled in b: t-e A! Anal'st;
Section * s-o)ld be filled in b: t-e Supplier (lines 79 to 7E)6 nter t-e )pplier >a*e in t-eappropriate cell and enter t-e na*e and date of t-e a)t-ori5ed )pplier Representative -o is fillin% int-e for*;
Section C s-o)ld be filled in b: t-e A!6 (f t-e part co**odit: is exe*pt see xpress for* forcriteria6< it s-o)ld be listed in t-e Co**odit: xe*ption letter si%ned b: t-e )pplier ")alit: ana%er;T-is is expected to be one letter listin% all exe*pted co**odities and stored in one location forreference b: all of )pplier ")alit:;
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D#(P&I Supplier +uality F%#A S#B#RI), RAN'IN$S
Note E"9 Any Failure %ode a11ecting the Behicle Assebly Plant M"#T be ranked an 6G or higher.Note E9 Any Failure %ode a11ecting a Delphi Plant M"#T be ranked 3G or higher.
Select 1ro the categories belo=< using the highest applicable ranking.
Ranking #11ect #nd Custoer Behicle Assebly Plant Delphi Plant Supplier Plant
10 Ha5ardo)sit-o)t arnin%
$otential fail)re *ode affectssafe ve-icle operation and/orinvolves nonco*pliance it-%overn*ent re%)lation it-o)tarnin%;
$otential fail)re *ode *a:ca)se )nsafe condition forplant personnel it-o)tarnin%;
$otential fail)re *ode *a:ca)se )nsafe condition forplant personnel it-o)tarnin%;
$otential fail)re *ode *a:ca)se )nsafe condition forplant personnel it-o)tarnin%;
9 .a0ar'o(s-wit$
war#i#g
$otential fail)re *ode affectssafe ve-icle operation and/or
involves nonco*pliance it-%overn*ent re%)lation it-arnin%;
$otential fail)re *ode *a:ca)se )nsafe condition for
plant personnel it- arnin%;
$otential fail)re *ode *a:ca)se )nsafe condition for
plant personnel it- arnin%;
$otential fail)re *ode *a:ca)se )nsafe condition for
plant personnel it- arnin%;
8 ery .ig$ De-icle/ite* inoperable 4lossof pri*ar: f)nction6S fail)re*ode *a: ca)se c)sto*eral. -o*e< field ret)rn< ord)rabilit: iss)e;
$otential fail)re *ode *a:ca)se a spi ll/*aEor disr)ption<repair< asse*bl: diffic)lt:<reor.< or sortin% at t-eDe-icle Asse*bl: $lant
$otential fail)re *ode *a:ca)se a spill/*aEor disr)ptionat a 7elp-i $lant;
7 .ig$ De-icle/ite* operable b)t at ared)ced level of perfor*ance;C)sto*er ver: dissatisfied;#ail)re *ode *a: ca)seve-icle repairs at 7ealer;(ncl)des >oise iss)es
4s@)ea./rattle6;
9ee >ote N1
$otential fail)re *ode *a:ca)se repair< asse*bl:diffic)lt:< reor.< sortin% at a7elp-i plant;
6 o'erate De-icle/ite* operable b)tco*fort/convenience ite*4s66inoperable/not perfor*in% toc)sto*er expectation 4e;%;;>oise6
9ee >ote N1
$otential fail)re *ode *a:ca)se special -andlin% ofco*ponents at 7elp-i9;
5 ow De-icle/ite* operable b)tco*fort/convenience ite*4s6operable at a red)ced level of perfor*ance;
9ee >ote N1$otential fail)re *ode *a:ca)se inconvenience to 7elp-iprior to asse*bl:;
4 ery ow #it and finis- ite* does notconfor*; 7efect noticed b:*ost c)sto*ers;
9ee >ote N19ee >ote N2
3 i#or #it and finis- ite* does notconfor*; 7efect noticed b:avera%e c)sto*ers;
9ee >ote N19ee >ote N2
2 ery i#or #it and finis- ite* does notconfor*; 7efect noticed b:discri*inatin% c)sto*ers;
9ee >ote N19ee >ote N2
1 No#e >o effect; 9ee >ote N1 9ee >ote N2
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$robabilit: +i.el: #ail)re Rates $p. Ran.in%
Der: Hi%-= $ersistent #ail)res
100 per t-o)sand pieces
!0 per t-o)sand pieces
0;!!
L 0;!!
10
9
Hi%-= #re@)ent #ail)res
20 per t-o)sand pieces
10 per t-o)sand pieces
L 0;78
L 0;8
8
7
oderate= 'ccasional #ail)res ! per t-o)sand pieces
2 per t-o)sand pieces
1 per t-o)sand pieces
L 0;94
L1;00
L1;10
!
4
+o= Relativel: #e #ail)res 0;! per t-o)sand pieces
0;1 per t-o)sand pieces
L1;20
L 1;30
3
2
Re*ote= #ail)re is )nli.el:
0;001 per t-o)sand pieces G
L 1;7 1
>ote= (dentical to an)al except for Ran.in% of 1; an)al allos for ;01 per t-o)sand 10 $$6
/P) (!!lier (ality = ;@N =@=<);N =NK)N>
am!le "al"(latio# to 'etermi#e P!& al(e *rom a li&ely *ail(re rate o* 5 !er t$o(sa#' !ie"es see = t$ir' =!!e#'iA ).
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Ran.in% ffect $#A
10
Absol)te ncertaint: Cannot detect or is not c-ec.ed;
9 Der: Re*ote Control is ac-ieved it- indirect or rando* c-ec.s onl:;
8 Re*ote Control is ac-ieved it- vis)al inspection onl:;
7 Der: +o Control is ac-ieved it- do)ble vis)al inspection onl:;
+o Control is ac-ieved it- c-artin% *et-ods< s)c- as $Ctatistical $rocess Control6 OR %a)%in% perfor*ed on set)p andfirstpiece c-ec.; G
! oderate Control is based on variable or attrib)te %a)%in% perfor*ed100I of t-e parts after parts -ave left t-e station;
4 oderatel: Hi%- rror detection in s)bse@)ent operation; G
3 Hi%- rror detection instation< or error detection in s)bse@)ent
operations b: *)ltiple la:ers of acceptance= s)ppl:< select<install< verif:; Cannot accept discrepant part;
2 Der: Hi%- rror detection instation a)to*atic %a)%in% it- a)to*atic stopfeat)re6; Cannot pass discrepant part;
1 Al*ost Certain iscrepant parts cannot be *ade beca)se ite* -as been errorproofed b: process/prod)ct desi%n;
G >ote= (dentical to an)al except for Ran.in%s of and 4; &ords U'R %a)%in% perfor*ed on set)p and first piece c-ec.V*oved fro* a detection of 4 to a detection of
D#(P&I Supplier +uality F%#A Detection Rankings