Customer Specific and Proterra Risk Assessment carried out by Prototype Shop feasibility study
Requirements input by Advance Program Management provided by quality prototype shop
Quality
Customer APQP Minutes with CSRs, Special
Checklist Kick-off meeting with supplier. Characteristics, and
Update CSRs and time specifications distributed to
schedule team.
Customer PPAP
Checklist VDA2
Adjust APQP Checklist
APQP Kick-off according to CSRs. Start
sign-in sheet
tracking of APQP Checklist.
Getting Started OUTPUTS Gate 0 - Program Concept
Phase 0 - Program Initiation 0.1 Organize the Team Ensure Customer needs and • 0.1 APQP Risk Assessment
(A-0 APQP Risk Factors Checklist) expectation are clearly understood (A-0 APQP Risk Factors Checklist)
(APQP Kick-Off) Design goals • 0.2 Define the Scope
0.2 Define the Scope Reliability and quality goals • 0.3 Team-to-Team
0.3 Team-to Team Comm Preliminary BOM • 0.4 Training
0.4 Training Preliminary process flow chart • Sourcing
0.5 Sourcing Preliminary listing of special products • Technology Requirement Assessment
(A-9 Sourcing Checklist) and process characteristics • Facility and Infrastructure Readiness
0.5.1 High-Risk Supplier Evaluation Product assurance plan Assessment
0.6 Customer and Organization Capacity Planning • Resources Readiness Assessment
Involvement Change Mgmt Implementation • Sourcing Assessment
0.7 Simultaneous Engineering APQP Metrics • Styling/Appearance Assessment
0.8 Control Plans Risk Assessment Mitigation • Timing Plan Assessment
0.9 Concern Resolution Plan
Planning and implementation (Analytical Techniques-App C) • Program Mgmt
0.10 Product Quality Timing Plan Approval
0.11 Plans Relative to the
Timing Chart
Incomplete
Incomplete
Phase 0
Gate Review
Pass
Phase 1 - Plan and Define INPUTS Program Risk Assessment Gate 1 - Program Approval
Voice of the Customer 1.1.2 – Quality info and any historical 1.12 Product Assurance Plan
- Market Research warranty 1.13 Capacity Planning
- Historical warranty and Quality 1.2 Business Plan and Strategy 1.14 Leadership Support Plan
informaiton 1.5 Product Reliability Studies 1.15 Change Management (Log)
-Team Experience 1.6 Customer Inputs 1.16 APQP Program Metrics
Customer inputs (CSRs) to include 1.7 Design Goals 1.17 Risk Assessment and Mitigation Plan
Regulatory Mandates, Lessons 1.8 Reliability and Quality Goals • Facilities and infrastructure Readiness
Learned 1,9 Preliminary BOM Plan
Business Plan/Marketing Strategy 1.10 Preliminary Process Flow • Resources Readiness Plan
Product/process Benchmark Data 1.11 Prelim ID Product and Process Spec • Supplier Sourcing & Readiness Plan
Product/process assumptions Char • Program Timing Plan
Product reliability 1.12 Product Assurance Plan • Lessons Learned
1.13 Capacity Planning
1.14 Leadership Support Plan • Approvals - Sign Off
"Ensure Customer needs and 1.15 Change Management Log
1.16 APQP Program Metrics1.17 – 1.17
expectation are clearly
1.17 Risk Assessment Mitigation Plan
understood" • PLANT FACILITY AND INFRASTRUCTURE
READINESS PLAN
• RESOURCES READINESS PLAN SUPPLIER
SOURCING & READINESS PLAN
• PROGRAM TIMING PLAN
The APQP program metrics is an honest and critical point overview document
managed and completed by the project team manager meant to summarize the program
for management.
Incomplete
Phase 1
Gate Review
Pass
Phase 2 - Design Development INPUTS (Derived from Phase 1) Program Steps Gate 2 - Design Feasibility
Design goals 2.1 Design FMEA • DFMEAS
Reliability and quality goals (AIAG/VDA FMEA Manual) • DFMA&S
Preliminary BOM (DFMEA Checklist Appendix A-1) • Design Verification
Preliminary process flow chart 2.2 Design for Manufacturability, • Prototpe Build
Preliminary listing of special products Assembly and Service • Control Plan Approval
and process characteristics (Design Info Checklist in Appendix A-2( • Specifications Review
Product assurance plan 2.3 Design Verification • New Equipment , Tooling & Facilities
Capacity Planning 2.4 Design Reviews Requirements
Leadership Support (See Appendix C for DOE, test to failure of • Special Product and Process
Change Mgmt Implementation Special Characteristcs, and analytical Characteristics
APQP Metrics techniques) • Gage and Test Equipment Requirements
Risk Assessment 2.5 Prototype Build Control Plan • Tiered Supplier Design Review
Mitigation Plan 2.6 Engineering Drawings • Lessons Learned Implementation
(Including Math Data)
"Comprehensive and critical 2.7 Engineering Specifications • Approvals - Sign Off
review of engineering 2.8 Material Specifications
requirements" 2.9 Drawing and Spec Changes
2.10 New Equipment, Tooling and
Facilities Requirements
(Tooling and Test Equip Checklist A-3)
2.11 Special Product and Process
Characteristics
(Control Plan Spec Char Appendix C)
2.12 Gages/Testing Equipment
Requiremenst
Incomplete
Phase 2
Gate Review
Pass
Phase 3 - Design Verification INPUTS (Derived from Phase 2) Program Steps Gate 3 - Process Feasibility
Design FMEA 3.1 Packaging Standards and • Product/Process Quality System Review
Design for Manufacturability, Specifications • Process Flow Chart
Assembly, and Service 3.2 Product/Process Quality System • Floor Plan Layout
Design Verification Review • PFMEA
Design Reviews (Product/Process Quality Checklist • Pre-Launch Control Plan Approval
Prototype Drawings (w/Math Data) Appendix A-4) (Customer Approved Y/N/NR)
Enginering Specifications 3.3 Process Flow Chart • Process Instructions
Material Specifications (Process Flow Chart Checklist Appendix • Gage and Test Equipment
Drawings and Specifications Changes A-6) Measurement System Analysis Plan
New Equipment, Tooling and Facilities 3.4 Floor Plan Layout (Floor Plan • Preliminary Process Capability Study
Requirements Checklist in Appendix A-5) Plan
Special Product and Process 3.5 Process FMEA (Process FMEA • Tiered Supplier Process Review
Characteristics Checklist in Appendix A-7) (PFMEA, CP, MSA, Ppk-Spec Char)
Gages/Testing Equipment 3.6 Pre-Launch Control Plan (Safe Launch • Lessons Learned Implementation
"Ensure comprehensive Requirements Plan during Pre-Launch - Section 4.7) and
developmentof an effective Team Feasibility Commitment (Control Plan Checklist in Appendix A-10) • Approvals
and Leadership 3,7 Process Instructions
manufacturing system"
Support 3.8 Measurement Systems Analysis Plan
(Refer AIAG MSA Manual)
3.9 Preliminary Process Capability Study
Plan (Refer AIAG PPAP
Manual)
3.10 Leadership
Support
Incomplete
Phase 3
Gate Review
Pass
Phase 4 - Product/Process INPUTS (Derived from Phase 3) Program Steps Gate 4 - Launch Readiness
Validation Packaging Standards and 4.1 Significant Production Run with • Preliminary Process Capability Study
Specifications Ppk, MSA, Run-at-Rate,Packaging, FTC, • Production Control Plan Approval
Product/Process Quality System FTQ, Master Samples, and Signoff • Initial Production Sample Characteristic
Review 4.2 Measurement System Analysis (Refer Category - dimensional, visual,
Process Flow Chart to AIAG MSA Analysis manual) laboratory, performance
Process Flow Chart to AIAG MSA Analysis manual) laboratory, performance
Floor Plan Layout 4.3 Preliminary Process Capability Study • Gage and Test Equipment MSA
Process FMEA (Refer AIAG PPAP and SPC manuals) • Process Monitoring-Process Sheets and
Pre-Launch Control Plan 4.4 Production Part Approval Visual Aids
Process Instructions (Refer to AIAG PPAP Manual) • Packaging and Shipping
Measurement System Analysis Plan 4.5 Production Validation Testing • Significant Production Run
Preliminary Process Capability Study 4.6 Packaging Evaluation • Tiered Supplier Readiness for Ppk of
Plan 4.7 Production Control Plan Special Characteristics, Control Plan,
Leadership Support (Refer to AIAG Control Plan Manual) MSA, Significant Production Run
4.8 Quality Planning Sign-Off and
Leadership Support: Contains Process
"Validating the manufacturing
Flow Charts, Control Plans,Process
process through evaluation of Instructions, Monitoring and Measuring
a significant production run" Devices verified with GR&R and MSA,
Capacity Run-at-Rate, customer sign-off
on Product Quality Planning Summary and
Approval
report in Appendix E.
Incomplete
Phase 3
Gate Review
Pass
INPUTS (Derived from Phase 4) Program Steps Gate 5 - Feedback, Assessment and
Phase 5 - Feedback, Assessment and
Significant Production Run 5.1 Reduced Variation Corrective Action
Corrective Action
Measurement System Analysis (Refer to AIAG SPC Manual) • Process Capability Study (Cpk for
Preliminary Process Capability Study 5.2 Improved Customer Satisfaction Special Characteristics and others)
Production Part Approval (Refer to AIAG PPAP Manual Sect 3.1) • Production Control Plan Aproval
Productioon Validation Testing 5.3 Improved Customer Service and (Approval to end Safe Launch)
Packaging Evaluation Delivery • Lessons Learned Incorporation
Production Control Plan 5.4 Effective Use of Lessons Learned and - Current part (FMEA,CP/WI)
Quality Planning Sign-Off and Best Practices to include: - Family/Foundaion FMEAs/CPs
Leadership Support • Review of TGW/TGR - "Read Across" System Updated
• Data frin /warranty and performance
metrics • Approvals
• Corrective Action Plans
• "Read Across" with similar product and
processes
"Evaluate the effectiveness of • DFMEA and PFMEA studies
the product quality planning • Preservation of institutional knowledge
the product quality planning • Preservation of institutional knowledge
via permanent documentation of error-
effort"
proofing solutions
(Refer to AIAG&VDA FMEA manual Sect
1.3.6 Foundation and
Family FMEAs for detail)
