This printed document is an UNCONTROLLED COPY - Check Operating System to verify validity prior to use Date printed: 5/30/2005

SOP-_____ Product Realization

Engineering Site Manufacturing Site
4.2.1.2 Product Creation Process
As applicable, 4.2.1.3 Special Characteristics
Approved Program Package
Statement of Requirements (SOR/SOW)
D 4.2.1.13 Packaging, Shipping and Labelling

Functional & performance requirements 6.2.2.1 Product Design Skills

7.1.1 Planning of Product Realization - Supplemental
statutory & regulatory requirements
7.1.2 Acceptance Criteria
information derived from other similar 7.3.1 Design & Development Planning
designs
targets for product quality, life reliability,
durability, maintainability, timing & cost
Director of Program Management/Product Engineering Supervisor and Division General Manager
SOR - Customer Requirements (including Identify the product design and development stages and key dates (ensuring plans are updated, as
Contract Review output) applicable, throughout the program)
Customer Technical Specifications
Special Characteristics
Determine the review, verification and validation activities that are appropriate to each design and

Phase 3 - Product - Design, Development & Verification

Identification, Traceability & Packaging development stage, including customer acceptance criteria.
Requirements Define multidisciplinary team members
Customer-specified Definitions and
Symbols
Assign the respective responsibilities and authorities for product design and development ensuring that
Deliverable Assignment Matrix design personnel are competent to achieve design requirements and are skilled in applicable tools and
White Papers techniques
Product Assurance Plan (PAP) Manual
Identify applicable tools and techniques to design product
Customer Process Sign-Off (PSO) Manual
Establish the interfaces between groups to ensure effective communication and clear assignment of
responsibility As applicable,
Records of review
Master Timing Schedule
Cost targets & budget allocations
As applicable, Resource Requirements
Customer requirements (contract review), such as special Program Team assignments
characteristics, identification & traceability Updated Deliverables Assignment Matrix
performance , functional requirements Updated planning documents
FMVSS & Customer Engineering Standards Program objectives
Quality Function Deployment
Historical References: information gained from previous
design projects, competitor analysis, supplier feedback,
internal input, field data, etc. 7.3.2 Design & Development Inputs
Targets for product quality, life, reliability, durability, 7.3.2.1 Product Design Input (Review)
7.3.4.1 Monitoring
maintainability, timing, cost. Program Manager, Chief Engineer and
Lead Engineers review all Design
& development inputs to ensure that requirements are complete,
unambiguous, & not in conflict with each other & further identifies the
measurements to be monitored, analyzed & reported
to Management for their review As applicable,
Review Records
Design Phase Input Design Plan & Schedule
Documents Functional Objectives
Performance Requirements
Engineering ensures that all design Lessons learned
input documents are adequate Benchmarking Data
Competitor analysis results
Styling Objectives
Documents Craftsmanship Objectives
No
adequate? Build Objectives
4.2.1.15 Control Plans
4.2.1.3 Special characteristics not identified with
Symbols
4.3.1 Environmental Aspects
As applicable,
Customer Requirements SOR (Contract Review) Yes 6.4.1 Personnel safety to achieve Product Quality
such as Special Characteristics, Identification, 7.3.2 Design & development inputs
7.3.2.1 Product Design Input (Review)
Traceability, Packaging
7.3.3 Design & Development Output
Customer Engineering Standards (PS, PF, MS etc) 7.3.4.1 Monitoring
Internal Corporate Standards
Applicable Statutory & Regulatory Requirements
Customer Product Requirements Product Design Engineers design product ensuring that the design output:
Forward & Rearward Impact meets the input requirements for design & development
Load Fatigue is expressed in terms that can be verified & validated against product design input requirements
Ingress/Egress
identifies all special product characteristics
Bounce/Jounce
BSR Targets Complies with customer-specified definitions & symbols
Effort Requirements provides appropriate information for purchasing, production and for service provision
Functional Objectives contains or references product acceptance criteria
Craftsmanship Objectives addresses product safety and reduction of potential risks to employees
Comfort Requirements specifies product characteristics that are essential for its safe & proper use
H-point Targets
incorporates consideration of quality and environmental components into design activities
Contour/STO
Build objectives specifies product characteristics that are essential for its safe & proper use
Information/data from previous design projects if applicable, incorporates knowledge gained from previous contracts
(lessons learned) competitor analysis, supplier As applicable,
feedback, internal input, field data, and other Engineering Drawings (product definition) /math data
Special Characteristics
relevant sources Design FMEA
targets for Product quality, life, reliability, durability, Reliability results
maintainability, timing, and cost Product error-proofing, as appropriate
MID issues (manufacturing issues)
Go to Prototype Control Plan
Ride & Drive Evaluation Results BOM
Product Design Review Results
Product Environmental Information (31) diagnostic guidelines, where applicable
Information for purchasing, production & service provision
E - Product Consider results from Product Campaign Notification
Response where applicable
Design Reviews DVP&R Results
RSRC Update

ABC Corporation - Operating System SOP-____ Product Realization Process, Revision: 1 Page: 4 - Phase 3
This printed document is an UNCONTROLLED COPY - Check Operating System to verify validity prior to use Date printed: 5/30/2005

SOP-_____ Product Realization

Engineering Site Manufacturing Site
Program Overview
Design Phase Requirement Documents:
Health Charts
E 4.2.1.7 Design Verification & Production
Forward & Rearward Impact Requirements Validation
Load Fatigue
Torque Requirements
Ingress/Egress 7.3.4 Design & Development Review
Bounce/Jounce 7.3.4.1 Monitoring
BSR Targets 7.3.5 Design & Development Verification
Effort Requirements
Functional Objectives
Craftsmanship Status
Comfort Requirements
At suitable stages,
H-point Targets Product Design Engineering Manager & Chief Engineer
Contour/STO
Build Objectives (MID) facilitates Critical Design Review of design output
DVP&R Test Status with representatives of functions concerned with the product

Phase 3 - Product - Design, Development & Verification

MITS Status
Warranty Data design and development stage(s) being reviewed to ensure :
Continual Improvement Plan that the design & development output satisfy input requirements
provide appropriate information for purchasing, production and for service provision
that product acceptance criteria is identified or referenced
that characteristics of the product that are essential for its safe & proper use are specified
the ability of the results of design and development to fulfill requirements is evaluated
identify any problems and propose necessary actions
4.1.3 Design Changes
evaluate issues/change proposals
records of the results of the review, & any necessary actions are maintained
7.1.4 Change control
As applicable,
7.3.7 Control of Design
& Development Changes Design Review Records (Input to Management
Review)
Modified Master Program Timeline
Product Design Engineer Best Practice Database Updates
implements required changes Lessons Learned
(per SOP-______ Change Control) DVP&R Test Results Action Plan
Yes Action Plans

Yes Issues
identified and/or actions
required?
Changes
Required? No
7.1.1 Planning of Product Realization -
Supplemental
Phase Deliverables 7.3.4 Design & Development Review
Customer 7.3.4.1 Monitoring
Customer Approval
Yes
Reviews Designs Required? Program Manager convenes
Multi-disciplinary Team for Phase Review 3
No in preparation for Executive Review 2, ensuring that:
Required all Phase Deliverables are met
No
Approvals outstanding issues are identified
gap analysis is performed
Product Design Engineer all documentation is current
releases approved records of review are documented As applicable:
Phase Deliverables Summary Report
documents As applicable, and maintained Phase Deliverables Assignment Matrix
Design FMEA, reliability results Phase/Gate Review Exit Approval
Engineering Drawings Lessons Learned Report
Engineering specifications & Phase Review Report
standards
Program Manager Design Verification Plan

ensures that all

Phase requirements
are met or, as All items
No
applicable, carried closed-out?
forward for
subsequent phase
verification.
Yes
Tool Investment Approvals (Customer/Corporate)
Manufacturability confirmed by Plant Manager 7.1.1 Planning of Product
Customer Approved Concept Design & Process Realization
7.3.4 Design &
As applicable Executive Review 2 Development Review
Deliverable Summary Report
General Manager/VP Director 7.3.4.1 Monitoring
of Engineering/VP Sales, Program
Manager, Financial Champion, & Operations VP
convene Multi-disciplinary Team to review:
Deliverables List -Issues List
Budgets vs. Actual -Staffing
Readiness for Phase 4 -Key Metrics As applicable:
Key Metrics -Exceptions List Phase Deliverables Summary Report
Phase Deliverables Assignment Matrix
Product Specifications -GD&T Identified Phase/Gate Review Exit Approval
SOW 100% Lessons Learned Report
Phase Review Report
Risk & Opportunity List

Engineering Site Manufacturing Site:

Phase 5 -
Product Design Validation
I Go to Go to F Phase 4 - Manufacturing
Process Development

ABC Corporation - Operating System SOP-____ Product Realization Process, Revision: 1 Page: 5 - Phase 3
This printed document is an UNCONTROLLED COPY - Check Operating System to verify validity prior to use Date printed: 5/30/2005

Operating System

Name: Start Name: Activity Rectangle Name: Review or Inspection Name: Decision

Prompt: Identifies the initiation Prompt: Describes individual Prompt: Identifies review or Prompt: Indicates a decision
point of the described responsible, process inspection activities. where a choice
process or activity to be Usually followed by between two or more
performed and decision diamond. paths must be taken.
associated processes
(as applicable)
Start

Name: ISO/TS 16949-related Name: ISO 14001-related Name: Customer-specific Name: Process Input
requirements
Prompt: Identifies specific sub- Prompt: Identifies specific sub- Prompt: Prompt: Documents/records
elements of the ISO/ elements of the ISO Identifies requirements which are required in
TS 16949 Standard 14001 Standard specified by General order to perform the
Motors Company described process

Name: Process Output Name: Resources Required Name: Examples Name: End

Prompt: Documents/records Prompt: Identifues resources Prompt: Use to identify typical Prompt: Identifies end of
which are generated required to perform examples of item proces
as a result of the process. mentioned in process
described process

End

Name: Yes Result Name: Bottom to top Name: Top/bottom to side

Name: No result variable
Prompt: Use in conjunction Prompt: Prompt: Connect the top or
with decisions. Type Prompt: Use in conjunction Connect the bottom bottom of one object
"Yes" or "No" to with decisions. Type of one object to the to the side of
indicate result. "Yes" or "No" to top of another. another.
indicate result.
Yes
No

Name: Side to top/bottom

Prompt: Connect the side of

one object to the top
or bottom of another.

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