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8/2/2019 SAQP Elements Overview
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Objectives
Supplier Development APQP
AQP Process
SAQE Responsibilities
Construction Of SAQP Workbook
Update & Review Procedure
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XConcept
Design
Supplier
Selection
Feasibility
Manufacture
PPAP
Deliver
Supplier Development APQP
Product / Process
Maturity
SAQER
esponsibility
0 Defects ?
0 Defects ?
90 Days of production
0 Defects ?
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Supplier Development APQP
PPAP APQP
Keep as Hard Copy in Folder or
Store on Computer
Backup or temporary storage of key
documents on Lotus notes database
Hard Copy in Folderor
Electronic copy on CD
Backup or temporary storage of key
documents on Lotus notes database
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APQP
Supplier Development APQP
PPAP submission approval & master samples31
PPAP Interim30
SPSO (supplier process sign-off) - Capacity Verification29
Product Validation Testing28
Material certification27
AAR (appearance approval report)26
Dimensional Report25
Process capability study & Status24
Gauge functionality, certification, & R&R (reliability and repeatability)23
Production trial run22
IMDS data base acceptance21
Drawing Release for PPAP (Design Freeze)20
1st Off Tool Parts & dim report19
Packaging specifications & shipping plan18
Subcontractor PPAP status17
Pre-launch containment plan16
Control plan & control plan special characteristics15
Process FMEA14
Process flow chart & manufacturing floor plan13
Pre-production build plan & purchase order cover12
Tooling kick-off & purchase order cover11
Gauge design & feasibility10
Tool & equipment design & feasibility9
Design FMEA (failure mode & effects analysis)8
Capacity plan7
Team feasibility commitment6
DVP&R (design verification plan & report)5
Drawing & specification review & quality objectives4
AQP kick-off meeting & contacts list3
LON (letter of Nomination)2
SSOW (supplier statement of work) / DSKO (directed supplier kick off)1
Microsoft Excel
Worksheet
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Supplier Development APQP
What is the purpose of the SAQP WorkbookTo provide a record of the current status for each element of the
AQP process, and to ensure that all outstanding issues have been
identified and allocated an owner for corrective action with
completion date.
It is not the Intention of the workbook to be the method tocommunicate issues to the SDT
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Supplier Development APQP
Supplier
Develops
process
SupplierUpdates Workbook
SAQE Reviewsprocess and
checks workbook
Manages Issues
EPIC is updated with
StatusSDT Review
Keeps SDT
informed
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Supplier Development APQP
1. S.S.O.W. / D.S.K.O. & Contacts List2. L.O.N. (Letter of Nomination)
Review SSOW paying particular attention to Program Timing
Project Scope Parts Matrix Rolls and responsibilities.
A list is created to identify all project responsible
contacts, including telephone numbers andlocation. Include:
Program MGR
Buyer Quality Logistics Engineering
What to KeepMeeting minutes
DSKO
Sample of SSOW
Sample of the Letter of Nomination
Note
The SSOW must be signed by both Supplier andJCA at beginning of project, and failure to comply
must be a RED issue.
Target
To ensure that the supplier
has the correct information
to develop the product to
achieve cost and quality
objectives over the product
life.
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Supplier Development APQP
3. AQP Kick off Meeting
NoteAny changes from the agreed timing
must be done on the Issue / Action
section of the worksheet.
Target
Workbook is updated with
planned dates for each
element and these remain
fixed target for the
duration of the project.
What to Keep
SAQP report
SAQP Workbook
The APQP kick-off meeting allows supplier to interact with
the JCI launch team and opens the lines of communication
between the various functions.
The frequency of regular meetings is established.
The supplier is responsible at the APQP kick-off meeting to
either:1) Review with the launch team the names and dates
provided on a completed APQP timing summary.
2) Agree key dates, which are later referenced when
completing the form with names and dates.
The established target start and completion dates must never
be changed, but rather compared with the actual start andcompletion dates to assess the overall execution success of
the original plan.
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Supplier Development APQP
What to Keep
DVP Report
FER_DVP
5. DVP&R(Design Verification Plan & Report)
The DVP&R is a summary of all development
testing required to ensure the product conforms to
defined customer needs and requirements. Testing
results are incorporated into the document as they
become available.
Target
All design defined material
and functional tests are
compliant
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Supplier Development APQP
What to Keep
Feasibility report
FER_Feasibility
6. Team Feasibility Commitment
NoteFeasibility confirmation is needed
after each engineering change
Target
Supplier agrees requirements
can be manufactured to
required quality in serial
conditions to the planned
volume
All Important characteristics
to be measured and monitored
appropriately
It is the responsibility of supplier to assess the
feasibility of the proposed JCI design and/or product.
Supplier must confirm the product can be
manufactured as proposed and will meet the specifiedquality, cost, and delivery terms. The team feasibility
consensus is documented and includes a list of all
open issues.
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Supplier Development APQP
7. Capacity Plan
Ensure the suppliers plan to achieve capacity is based
on the Peak volumes from SSOW and is achievable.
For Component suppliers.
Load the planned cycle times into the Master CapacityPlan. Ensure all other components on specified process
are also included.
For Assembly Suppliers
Complete OEE with planned cycle time
Target
To ensure that the supplier
has the capacity to produce
product at the quoted
values + 20% peak volume
What to Keep
1.A Master Capacity Plan
1.B OEE data sheet
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Supplier Development APQP
9. Tool & Equipmentdesign & feasibility
NoteSAQE to monitor supplier
management of tool manufacture to
achieve tooling milestones
Target
Tooling manufactured is
designed to produce
expected quality parts for
product life.
What to Keep
Tool tracker or approved alternative
Review the suppliers plans for tooling and / or
equipment to ensure suitability for quality and
project life.
All SC & CC should have Poke Yoke included
in design to eliminate concerns.
For complex tooling or Equipment the Tooling
specialists should be involved in this review.
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Supplier Development APQP
10. Gauge Design & Feasibility
NoteAll SC & CC must be gauged
preferably with variable result. On-
going SPC should be done off gauge.
Target
The gauges and fixtures
used to determine quality,
should be available for 1st
off tool parts.
SC & CC should be
measurable from the gauges
and used in the capability
studies.
What to Keep
Gauge plan
The gauge system review ensures necessary
characteristics are checked, and that calibration
requirements, gauge maintenance plans, and
financing are established. The approval to begin
gauge construction is issued at this meeting. All
customer and JCI owned gauges must be identified
as such.
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Supplier Development APQP
11. Tooling KO & PO Cover
Ensure that All Tooling has been Kick off in
time to achieve PPAP, Purchase Order coverage
for all production tooling and equipment is
available.
A Timing plan is generated to review tool &
Equipment development.
For complex tooling, involvement of the SD
tooling team is required.
TargetTo ensure the tooling Is
kicked off in time to achieve
time plans
What to Keep
No specific document is used but a matrix ofall tooling and equipment with completion
dates would be required.
Tool Tracker
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Supplier Development APQP
12. Pre Production Build plan
& PO cover TargetSupplier has a plan to
manufacture parts for key
build dates and understands
delivery requirements.
Purchase orders are in
place to cover all pre
series and testing parts
What to KeepNo specific document defined,
A plan of the pre-production build
requirements, including parts for testing mustbe communicated. Purchase order for the parts
should have been issued.
The project buyer should maintain a list of PO
cover
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Supplier Development APQP
13. Process Flow Chart(Including floor plan)
Note SafetyAny part of process that has implications
on safety should be clearly identified.ie.
Welding Parameters
Material Hardening or Conditioning
!
A pictorial representation showing all of the steps of a
process. This must include detail of all points where
SC & CC are influenced and all material movement,
storage. Welding and surface treatment should beclearly identified
A floor plan with flow lines depicting material
movement should be included
TargetTo establish the
manufacturing route plan
and the movement and
storage that could have
impact on quality anddelivery.
This forms the structure to
develop the PFMEA
What to Keep
Process Flow Chart
Sample Floor plan
FER_MPFC
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Supplier Development APQP
14. Process FMEA(including mistake proofing)
Note - SafetyAll processes that effect product safety
should be given special attention forcontrol and .
Welding
Hardening
Surface Treatment
!
A PFMEA should be conducted during product quality
planning and before beginning production. It is a
disciplined review and analysis of a new/revised
process and is conducted to anticipate, resolve, ormonitor potential process problems for a new/revised
product program. A PFMEA is a living document and
needs to be reviewed and updated as new failure
modes are discovered.
TargetA formal review of all current
quality issues on similar
products should be documented
and aligned with review of new
product.This should be reviewed with the
known quality outputs from
similar products in production
and the lessons learned from
them must be completed and
What to Keep
PFMEA
FER_PFMEA
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Supplier Development APQP
15. Control plan
NoteControl plan must be in English or a
copy maintained in English.Specific attention should be made to
the ongoing control of SC & CC
!
The production control plan is a written
description of the systems for controlling parts
and processes. Particular attention should be
given to the control of special characteristics
The production control plan is a living
document and should be updated during the
development of the project from Prototype
Pre launch and production to reflect the
addition/deletion of controls based on
experience gained by producing parts.
(Approval from JCA is required.)
TargetIn conjunction with the
PFMEA all the key RPN issues
have controls applied to
ensure the failure does not
appear in production.
This includes all measurement
equipment and frequency of
checks likely to detect
failure.
What to KeepControl Plan
FER_Control plan
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Supplier Development APQP
16. Pre-Launch Containment PlanTarget0 defects during pre-launch
period
What to KeepMeasurement reports
Inspection reports
The pre-launch containment plan, is required to prevent
defect parts being sent to the customer during a period
where the process knowledge is developing. It contains
all information necessary to ensure customer
understanding of the quality delivered product.
This should include, but is not limited to:
Dimensional validation of delivered parts, including key
measurements including SCs & CCs
All deliveries are approved by a person who validates all
quality checks have been performed before despatch.
NoteSpecial Attention is needed for all
Welding and heat treatment
processes
!
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Supplier Development APQP
17. Subcontractor PPAP StatusTargetAll parts using in supplied
assembly are validated to
the same level as the
supplied part
What to Keep
Matrix of all sub-component PPAP Status
A key supplier launch responsibility is the
development and monitoring of sub-supplier quality
systems. To ensure the timely PPAP submission of
sub-contractor components this task is tracked in
program timing. The sub-contractor PPAP may alsobe reviewed in the run at rate/process sign off.
Supplier must track PPAP documentation for each
purchased component:
NoteAll SC & CC, Surface treatment,
Heat treatment, welding orconditioning must be traceable
through sub component approval.
!
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Supplier Development APQP
18. Packaging Specifications
& Shipping Plan
Note
TargetAn agreed method of packaging
to ensure all products are
received in perfect condition
What to KeepPackaging Specifications form
The product quality planning team ensures that
individual product packaging is designed, tested and
proven out. JCI packaging standards or generic
packaging requirements are to be used whereappropriate. In all cases, the packaging must ensure
that the product performance, appearance and
characteristics are not adversely affected by
handling and/or shipping. Packaging must be
compatible with all material handling equipment.
Product must be shipped via a JCI approved carrier.
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Supplier Development APQP
19. 1st Off Tool parts & Dim report,
NoteThe dimensional report can be from
CMM against CAD for this element
Once tooling is completed it is key to ensure the
tooling or equipment can produce a correct part, the
manufacturer must provide data to confirm the part
produced from the tooling is dimensionally correct
before delivery.
TargetTo ensure tool or process
manufactures a part to the
drawing at the earliest
opportunity.
What to Keep
Dimensional report
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Supplier Development APQP
20. Drawing Release for PPAPDesign Freeze
NoteAny changes not agreed in the PPAP
release cannot be implemented until
90 days after Job 1
TargetThe drawing released must be
compatible for the part being
PPAPd.
No changes to the design are
acceptable from this point
unless
with specific demand from
Customer with declared timing
implications
Or
Changes are needed to correctfunctionality.
What to KeepCopy of drawing to be included in PPAP
Feasibility form
The drawing released must be compatible for the
part being PPAPd.
there has to be agreement with program manager
what is the eng. level for PPAP - than thatengineering level has to be released via EPIC
S i A Q
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Supplier Development APQP
21. IMDS Data Base Acceptance
The supplier shall provide evidence that the
Material/Substance Composition reporting that is
required by the customer has been completed for
the part and that the reported data complies with all
customer-specific requirements.
TargetTo ensure that the
component data is accepted
by JCA in the data base.
The IMDS registration
number is recorded on the
PSW
The Number should also be
Recorded on the Workbook
in the comments for that
element
What to Keep
Copy of IMDS acceptance reportSample screen shot
NoteThe element is only complete when
the part is accepted on the data base
S li D l t APQP
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Supplier Development APQP
22. Production Trial Run
NoteData on production can be used for
initial understanding of capacity
For production parts, product for PPAP shall be taken
from a significant production run. This significant
production run shall be from one hour to eight hours of
production, and with the specific production quantity
to total a minimum of 300 consecutive parts, unless
otherwise specified by the authorized customerrepresentative. This significant production run shall be
conducted at the production site, at the production rate
(see Glossary) using the production tooling, production
gauging, production process, production materials, and
production operators. Parts from each uniqueproduction process, e.g., duplicate assembly line and/or
work cell, each position of a multiple cavity die,
mould, tool or pattern, shall be measured and
representative parts tested
TargetProcess runs under serial
production conditions to
approved control plan
What to Keep
Components for ISIR & Capability
Inspection reports
S li D l t APQP
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Supplier Development APQP
23. Gauge Functionality, Certification,R&R (Reliability And Repeatability
NoteALL gauges should be measured
using R&R including attributegauges
Where special gauges, fixtures, or test equipment
are required per the
control plan, verify gauge repeatability andreproducibility (GR&R) and proper usage.
TargetIt is important to ensure
that the gauge is detecting
error in the part not
variation error in how the
gauge is used to measure thepart.
What to Keep
R&R Study results
S li D l t APQP
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Supplier Development APQP
24. Process Capability Study
NoteSPC is a long term process and
needs to be continued on keycharacteristics
!
The purpose of this requirement is to determine if
the production process is likely to produce product
that will meet the customers requirements. The
initial process study is focused on variables not
attribute data. Initial capability must achieve a Cpkof 1.67 minimum with no special causes evident in
control chart
NOTE Unless approved in advance by JCA ,
attribute data is not acceptable for PPAP
submissions
Target
Validation that each of the
SC & CC applied to
dimensions is capable of
achieving its intendedtolerance for product life
What to Keep
Control chart (Analysed for special causes)
Histograms for distribution
List of all SC and Cpk PIPC (from CRT
agreement)
Supplier Development APQP
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Supplier Development APQP
25. Dimensional Report
NoteThe dimensional results for all 6
parts must be recorded separately
The supplier shall provide evidence that dimensional
verifications required by the design record and the
Control Plan have been completed and results indicate
compliance with specified requirements. The supplier
shall have dimensional results on 6 parts for each
unique manufacturing process, e.g., cells or
production lines and all cavities, moulds, patterns or
dies (see 2.2.18). The organization shall record, with
the actual results: all dimensions (except reference
dimensions), characteristics, and specifications as
noted on the design record and Control Plan.
TargetTo confirm that the
produced part conforms to
the drawing.
6 parts are measured and
the master samples should
be taken from these.
Remaining parts to be
available for testing.
What to KeepDimensional report
Material Test report
Supplier Development APQP
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Supplier Development APQP
26. AAR
(Appearance Approval Report)
NoteEach part and colour should be
measured and the values on AARmust be within design tolerances or
Master plaque whichever is agreed
A separate Appearance Approval Report (AAR)
shall be completed for each part or series of parts
if the product/part has appearance requirements onthe design record.
TargetCustomer approval of all
defined surface parts for
PPAP submission
What to Keep
AARSample
Supplier Development APQP
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Supplier Development APQP
27. Material Certification
NoteEnsure all planned material types
conform to design record includingregional variations before testing is
completed.
In addition to drawings and performance
specifications, material specifications should be
reviewed for Special Characteristics relating to
physical properties, performance, environmental,
handling, and storage requirements. Thesecharacteristics should also be included in the control
plan.
The supplier shall also submit a completed Design
Verification Plan and Report that summarizes
appropriate performance and functional test results.
TargetValidation that the material
used performs to the
expectation of the design
What to Keep
Material Report
Supplier Development APQP
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Supplier Development APQP
28. Product Validation TestingTargetComponent passes all test
capability and dimensional
requirements
Process achieves all
throughput and delivery
requirements
What to Keep
Records of compliance not retained in PPAP
PVT assures compliance to all JCI and/or
Customer requirements and is required for all
new or modified parts. The PV test samples
must be taken from a 300 piece production
simulated run incorporating production toolsand processes. PV testing may only begin
after all parts from external sub -suppliers
have PPAP approval, or have deviations
documented.
Supplier Development APQP
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Supplier Development APQP
29. SPSO
(Supplier Process Sign-Off)
NoteSPC is done in a controlled way to
an agreed plan.There is a reaction plan available for
adverse signals
!
TargetValidate the process can
produce 0 defect
production and planned
production speed .
All checking and control
documentation is in place
and operators are trained.
The supplier process sign-off (SPSO) verifies the
effective implementation of supplier quality
systems and evaluates suppliers manufacturing
readiness. The SPSO is initiated prior to the
supplier part submission to JCI. The advanced
quality engineer (or designate) will schedule and
lead the SPSO using the supplier process sign-off
form.
What to Keep
SPSO report WW-PLUS-FR-04-43
Supplier Development APQP
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Supplier Development APQP
30. PPAP InterimTargetThe target should always be
to not need Interim PPAP but
if there is no alternative,
then a mechanism must be
introduced to ensure thatthe issues are followed up
and full
PPAP introduced.
What to KeepDA
Corrective action plan
With agreement of Customer an Interim PPAP can be
signed with DA, but:
Each DA has to be signed by Program manager
For each DA there has to be plan for elimination of
the deviationDA number has to be mentioned on PSW
After DA is eliminated, a new PSW to be signed
NoteIssues like missing released drawings,
should not be covered by DA and if S-AQE
is asked to sign PPAP with those issues, S-
AQE should consult this with SDM before
PPAP signing off.
!
Supplier Development APQP
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Supplier Development APQP
31. PPAP Submission Approval
& Master Samples
NoteAn organization supplying standard catalogue
production or service parts shall comply withPPAP unless formally waived by theauthorized customer representative.
PPAP is developed to AIAG 4th Edition
PPAPs purpose continues to be to provide the
evidence that all customer engineering design
record and specification requirements areproperly understood by the organization and that
the manufacturing process has the potential to
produce product consistently meeting these
requirements during an actual production run at
the quoted production rate.
TargetThe purpose of PPAP is to
determine if all customer engineering
design record and specification
requirements are properly understood
by the organization and that the
manufacturing process has thepotential to produce product
consistently meeting these
requirements during an actual
production run at the quoted
production rate.
What to Keep
JCA Standard is submission level 3 refer to PPAP
presentation for retention requirements
Supplier Development APQP
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Supplier Development APQP
Task 1From the provided documents create an AQP folder
Task 2Create a SAQP Workbook from the folder and set status and
comments for each element