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Appendix Reference Revision

HOGW_4-2_SC-
1 Team Feasibility Commitment Letter(This is a link to the electronic
DIR_23-F01_EN
RFQ)
(Need Sharepoint
7-Feb-17
access to view)

2 APQP Open Issues Appendix_8 27-Apr-07


3 APQP Timing Plan Appendix_9 27-Apr-07
4 APQP Contact List Appendix_21 15-Feb-17
5 AIAG APQP Checklists Appendix_11 3-Nov-08
6 Program Review - Paper & Electronic Appendix_6_1 21-Nov-08
7 Program Review - Express Appendix_6_1 12-Mar-08
All Run@Rate Forms (R@R forms not included in the
8 APQP forms due to size)
Appendix_15 20-Feb-08
9 Aptiv PFMEA Severity Rankings QFP Training Website 6-Sep-05
10 Aptiv PFMEA Occurrence Rankings QFP Training Website 6-Sep-05
11 Aptiv PFMEA Detection Rankings QFP Training Website 6-Sep-05
APQP Open Issues
Supplier/Mfg
Location: Part Number(s)
:
Supplier Contact: Program(s)
:
Aptiv SQE Contact: Part Name:

Assigned
Issue Issue Issues Date/Status
No. Origin/Date Description and/or Sketch Responsibility Date

1.

2.

3.

4.

5.

6.

7.

8.
9.

10.

Progress Key:

Issue Identified Action Plan Proposed Action Plan Implemented Issue Resolved
sues

Forecast
Completion
Action Plan Date Progress
Issue Resolved
APQP Tim
Supplier Duns: Part Number(s):
Supplier/Mfg Location:

PPAP Date:

Supplier Contact: Description:


Supplier Telephone:
Tool Supplier
AQE/SQE Contact: (If applicable):
AQE/SQE Telephone: MY/Program:

Program Event Start Finish


Planned Actual
(mm/dd/yy)
(mm/dd/yy)
Planned
1)
Submit Team Feasibility Commitment Form
2)
Source Selection by Aptiv P.O. Issued
3)
Initiate APQP Activity
4)
Develop Product Quality Timing Plan
5)
Complete Preliminary Process Flow Diagram
6)
Complete Preliminary Listing of Special Product and Process Characteristics
7)
Design FMEA- Develop or Obtain Copy
8)
Design Review
9)
Review Specifications:Engineering, Material, Drawing
10)
Review Subcontractor APQP Status
11)
Complete Facility & Layout
12)
Complete Machinery & Equipment , Tooling Design & Build
13)
Prototype Builds
14)
Gage Reviews- Design, Build, R&R
15)
Submit Team Feasibility Commitment Form - Design
16)
Review Quality Systems-Procedures and Operator Work Instructions
17)
Complete Final Production Process Flow Chart
18)
Complete Process FMEA
19)
Complete Pre-Launch Control Plan
20)
Define Packaging Specifications
21)
Complete PPAP Production Run, Capability Studies, Production Control Plan
22)
Submit Supplier PPAP
23)
Conduct Run @ Rate
24)
Complete Early Production Containment Plan
APQP Timing Plan
(CL)
(CL)
(CL)

SOP Date:

Finish Status Comments

Actual
Potential Issues exists (comments must be noted)

Supplier Quality APQP Project Contact List

Supplier Code Manufacturing Address

Supplier Name

NOTE:  Supplier Profile Contact information should be reviewed and updated as changes occur.

Contacts Name and Title Mailing Address and E-Mail Address Contact Numbers

Sales Contact

Product Engineer

Quality Resident

Program Manager
in Sales Office

Program Manager
in Manufacturing Facility

APQP Contact

Quality Manager

Quality Engineer

Product Safety Officer

1st Shift Contact

2nd Shift Contact

3rd Shift Contact

PRR Response
Responsibility

Aptiv Engineering

Aptiv Buyer

Aptiv SQE
A-1 DESIGN FMEA CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

1 Was the DFMEA prepared using the Chrysler,


Ford and General Motors Potential Failure Mode
and Effects Analysis (FMEA) reference manual,
and applicable customer specific requirements?

2 Have historical campaign and warranty data been


reviewed?
3 Have best practices and lessons learned from
similar part DFMEAs been considered?
4 Does the DFMEA identify Special Characteristics?

5 Have pass-through characteristics (glossary) been


identified and reviewed with affected suppliers for
FMEA alignment and appropriate controls in the
supply base?

6 Have special characteristics designated by the


customer or organization been reviewed with
affected suppliers to assure FMEA alignment?

7 Have design characteristics that affect high risk


priority failure modes been identified?

8 Have appropriate corrective actions been assigned


to high risk priority numbers?
9 Have appropriate corrective actions been assigned
to high severity numbers?
10 Have risk priorities been revised when corrective
actions have been completed and verified?

Prepared By:
A-2 DESIGN INFORMATION CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

A. General
1 Does the design require:
a - New materials?
b - Special tooling?
c - New technology or process?
2 Has assembly build variation analysis been
considered?
3 Has Design of Experiments been considered?

4 Is there a plan for prototypes in place?

5 Has a DFMEA been completed?

6 Has a DFMA (Design for Manufacturability and


Assembly) been completed?
7 Have service and maintenance issues been
considered?
8 Has the Design Verification Plan been considered?

9 If yes, was it completed by a cross functional team?

10 Are all specified tests, methods, equipment and


acceptance criteria clearly defined and
understood?
11 Have Special Characteristics been selected?

12 Is bill of material complete?

13 Are Special Characteristics properly documented?


A-2 DESIGN INFORMATION CHECKLIST - CONTINUED

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

B. Engineering Drawings
14 Are reference dimensions identified to minimize
inspection layout time?
15 Are sufficient control points and datum surfaces
identified to design functional gages?
16 Are tolerances compatible with accepted
manufacturing standards?
17 Can existing and available inspection technology
measure all design requirements?
18 Is the customer designated engineering change
management process used to manage engineering
changes?

C. Engineering Performance Specifications


19 Have special characteristics been identified?
20 Are test parameters sufficient to address required
use conditions, i.e., production validation and end
use?

21 Have parts manufactured at minimum and


maximum specifications been tested as required?
22 Will all product testing be done in-house?

23 If not, is it done by an approved supplier?

24 Is the specified in-process performance test


sampling size and/or frequency consistent with
manufacturing volumes?
25 Has customer approval been obtained, e.g., for
testing and documentation, as required?
A-2 DESIGN INFORMATION CHECKLIST - CONTINUED

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

D. Material Specification
26 Are special material characteristics identified?

27 Where the organization is design responsible, are


specified materials, heat treat and surface
treatments compatible with the durability
requirements in the identified environment?

28 Where required, are the material suppliers on the


customer approved list?
29 Has the organization developed and implemented
a process to control incoming material quality?

30 Have material characteristics requiring inspection


been identified?
If so,
a - Will characteristics be checked in-house?
b - If checked in-house, is test equipment available?

c - If checked in-house, are competent people


available to assure accurate testing?
31 Will outside laboratories be used?

a - Does the organization have a process in place to


assure laboratory competency such as accreditation?
NOTE: Competency needs to be assured,
regardless of the organization's relationship with
the laboratory.

32 Have the following material requirements been


considered:
a - Handling, including environmental aspects?
b - Storage, including environmental aspects?

c - Have the materials/substance composition been


reported in accordance with customer requirements
e.g., IMDS?

d - Have polymeric parts been identified/marked per


customer requirements?

Prepared By:
A-3 NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

1 Does the design require:


a - New materials?
b - Quick change?
c - Volume fluctuations?
d - Mistake proofing?
2 Have lists been prepared identifying: (Include all
suppliers)

a - New equipment?
b - New tooling?
c - New test equipment (including checking aids)?

3 Have acceptance criteria been agreed upon for:


(Include all suppliers)

a - New equipment?
b - New tooling?
c - New test equipment (including checking aids)?
4 Will a preliminary capability study be conducted
at the tooling and/or equipment manufacturer?
5 Has test equipment feasibility and accuracy been
established?
6 Is a preventative maintenance plan complete for
equipment and tooling?
A-3 NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLIST - CONTINUED

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

7 Are setup instructions for new equipment and


tooling complete and understandable?
8 Will capable gages be available to run preliminary
process capability studies at the equipment
supplier's facility?

9 Will preliminary process capability studies be run


at the processing plant?
10 Have process characteristics that affect special
product characteristics been identified?
11 Were special product characteristics used in
determining acceptance criteria?

12 Does the manufacturing equipment have sufficient


capacity to handle forecasted production and
service volumes?
13 Is testing capacity sufficient to provide adequate
testing?
14 Has the measurement equipment been verified and
documented showing qualification for the required
scope of measurement and testing?

Prepared By:
A-4 PRODUCT/PROCESS QUALITY CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

1 Is customer assistance or approval required for the


development of the control plan?

2 Has the organization identified who will be the


quality liaison with the customer?
3 Has the organization identified who will be the
quality liaison with its suppliers?
4 Has the quality management system been reviewed
and approved per customer specific requirements?
5 Are there sufficient personnel identified to cover:
a - Control plan requirements?
b - Layout inspection?
c - Engineering performance testing?
d - Problem reaction and resolution analysis?
6 Is there a documented training program that:
a - Includes all employees?
b - Lists whose been trained?
c - Provides a training schedule?
7 Has training been completed for:
a - Statistical Process Control?
b - Capability studies?
c - Problem solving?
d - Mistake proofing?
e - Reaction plans?
f - Other topics as identified?
8 Is each operation provided with process
instructions that are keyed to the control plan?
A-4 PRODUCT/PROCESS QUALITY CHECKLIST - CONTINUED

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

9 Are standard operator instructions accessible at


each work station?
10 Do operator instructions include pictures and
diagrams?
11 Were operator/team leaders involved in developing
standard operator instructions?
12 Do inspection instructions include:
a - Easily understood engineering performance
specifications?
b - Test frequencies?
c - Sample sizes?
d - Reaction plans?
e - Documentation requirements?
13 Are visual aids:
a - Appropriate, easily understood and legible?

b - Available?
c - Accessible?
d - Approved?

e - Dated and current?


14 Is there a procedure to implement, maintain, and
establish reaction plans, for issues such as out of
control conditions based on statistical process
control?

15 Is there an identified problem solving process that


includes root cause analysis?
16 Are the latest drawings and specifications
available for the operator, in particular at the
points of the inspection?

a - Have engineering tests (dimensional, material,


appearance, and performance) been completed and
documented as required in accordance with customer
requirements?
A-4 PRODUCT/PROCESS QUALITY CHECKLIST - CONTINUED

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

17 Are the current forms/logs available for


appropriate personnel to record inspection results?

18 Are the following available and placed at the


appropriate points of the operation?
a - Monitoring and measurement devices?
b - Gage instructions? ✘

c - Reference samples?
d - Inspection logs?
19 Have provisions been made to certify and calibrate
gages and test equipment at a defined frequency
that is appropriate?
20 Have required measurement system capability
studies been:
a - Completed?
b - Accepted?
21 Have initial process capability studies been
conducted per customer requirements?
22 Are layout inspection equipment and facilities
adequate to provide initial and ongoing layout of
all details and components in accordance with
customer requirements?

23 Is there a documented procedure for controlling


incoming material that may include, for example,
the following items:
a - Characteristics to be inspected?
b - Frequency of inspection?
c - Sample size?
d - Designated location for approved product?
e - Disposition of nonconforming products?
24 Have sample production parts been provided per
customer requirements?
A-4 PRODUCT/PROCESS QUALITY CHECKLIST - CONTINUED

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

25 Is there a procedure to identify, segregate, and


control nonconforming products to prevent
shipment?
26 Are rework/repair procedures available to assure
conforming product?
27 Is there a procedure to requalify
repaired/reworked material?
28 Has a master sample, if required, been retained as
part of the part approval process?
29 Is there an appropriate lot traceability procedure?
30 Are periodic audits of outgoing products planned
and implemented?
31 Are periodic assessments of the quality system
planned and implemented?
32 Has the customer approved the packaging and the
packaging specification?

Prepared By:
A-5 FLOOR PLAN CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

1 Have lean concepts been applied in considering


material flow?
2 Does the floor plan identify all required process
and inspection points?
3 Have clearly marked areas for all material, tools,
and equipment at each operation been considered?
4 Has sufficient space been allocated for all
equipment?
5 Are process and inspection areas:
a - Of adequate size?

b - Properly lighted?

6 Do inspection areas contain necessary equipment


and record storage?
7 Are there adequate:

a - Staging areas?

b - Impound areas?

8 Are inspection points located to prevent shipment


of nonconforming products?

9 Are there controls for each process to eliminate


contamination or inappropriate mixing of
product?
10 Is material protected from overhead or air
handling systems contamination?

11 Have facilities been provided for final product


audit?
12 Are facilities adequate to control movement of
nonconforming incoming material?

Prepared By:
A-6 PROCESS FLOW CHART CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

1 Does the floor chart illustrate the entire process


from receiving through shipping, including outside
processes and services?

2 In the development of the process flow chart, was


the DFMEA used, if available, to identify specific
characteristics that may be critical?
3 Is the flow chart keyed to product and process
checks in the control plan and PFMEA?
4 Does the flow chart describe how the product will
move, i.e., roller conveyor, slide containers, etc.?
5 Has the pull system/optimization been considered
for this process?
6 Have provisions been made to identify and inspect
reworked product before being used?
7 Are material controls for movement and staging of
product including appropriate identification
properly defined and implemented? The controls
should address incoming supplier product as well
as subcontracted processes?

Prepared By:
A-7 PROCESS FMEA CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

1 Was the Process FMEA prepared by a cross


functional team? Has the team taken into account
all customer specific requirements, including
FMEA methodologies as shown in the current
edition of FMEA?

2 Have all operations including subcontracted, or


outsourced processes and services been
considered?

3 Have all operations affecting customer


requirements including fit, function, durability,
governmental regulations and safety been
identified and listed sequentially?
4 Were similar part/process FMEA's considered?

5 Have historical campaign and warranty data been


reviewed and used in the analysis?
6 Have you applied the appropriate controls to
address all of the identified failure modes?
7 Were severity, detection and occurrence revised
when corrective action was completed?
8 Do the effects consider the customer in terms of the
subsequent operation, assembly, and product?
9 Were customer plant problems used as an aid in
developing PFMEA?
10 Have the causes been described in terms of
something that can be corrected or controlled?
11 Have provisions been made to control the cause of
the failure mode prior to subsequent or the next
operation?

Prepared By:
A-8 CONTROL PLAN CHECKLIST

Customer or Internal Part No. Revision Level

Question Yes No N/A Comment/Action Required

1 Was the control plan developed according to the


methodology described in Chapter 6 of this APQP
manual?
2 Have all the controls identified in the PFMEA been
included in the control plan?

3 Are all special product/process characteristics


included in the control plan?
4 Were DFMEA and PFMEA used to prepare the
control plan?
5 Are material specifications requiring inspection
identified?
6 Does the control plan address incoming
(material/components) through
processing/assembly including packaging?

7 Are engineering performance testing and


dimensional requirements identified?
8 Are gages and test equipment available as required
by the control plan?
9 If required, has the customer approved the control
plan?
10 Are the gage methodology and compatibility
appropriate to meet customer requirements?
11 Have measurement systems analysis been
completed in accordance with customer
requirements?

12 Are sample sizes based upon industry standards,


statistical sampling plan tables, or other statistical
process control methods or techniques?

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Meeting Plan Checklist

AQE Input
Utilize Program Review Form -or -
Utlize Express Program Review Form
PPAP Requirements
R@R Timing and Requirements
Aptiv's Customer Specific Requirements
Introduction/Instructions to all Aptiv Supplier Websites.

Engineering Input
Latest part prints and specifications
Program Timing / Critical Characteristics
Technical Documents including sub-component drawings.
Program Information such as estimated annual usage, PPAP dates, SOP dates, etc.
Pilot and Prototype requirements and timing.
Key/Critical characteristics for PPAP

Buyer Input (from quote)


Packaging plan
Quoted Tool Capacity
Estimated Annual Volume

Supplier Input
Supplier Scorecard, be prepared to discuss
Updated supplier information (Supplier Profile)
including contact list.
Program Timing including tooling, PPAP, R@R
Supplier issues/concerns caused by Aptiv Aptiv.
Supplier issues/concerns not associated with Aptiv.
Questions/concerns needing to be addressed by Aptiv

Other Potential Supplier Input


Information on the manufacturing facility (Location, Capacity, etc.)

Preliminary Process Flow Diagram (PFD)

Preliminary Control Plan


Preliminary Timing Charts
Manufacturing Site Organizational chart
Subcontractors/Sub-Tier Mgt
Capability studies on similar parts.
Major disruptions, Problem Cases, PPM/Total Defects Reduction Plan
Tooling / Equipment Plans
Checking Fixture Plan
Prototype Plan
On-Going Product Assurance Testing
Preliminary PFMEA
Proof of Aptiv required quality certifications or transition plans
(Should be posted in Supplier Profile)

Description of Operator Training program


Plan for communication between technical support and manufacturing plant.
Completed Team Feasibility Commitment
Error Proofing/ Poke-Yoke Techniques
PROGRAM REVIEW SUMMARY
Link to AIAG Web Site
Date of Review:
Supplier :

Supplier Duns: Sub-Tier Supplier **:


** List if sub-tier supplier contributes more than 50% of manufacturing, controls a key pro
may be required for this supplier. Reference Team Feasibility document on RFQ.
Supplier/Mfg Location:
Critical process sub-tiers for heat treating, coating and plating must comply with the AIAG
to complete the assessments. See Section K

PART NUMBER DESCRIPTION MODEL Aptiv PLATFORM HIGH VOLUME


YEAR START OF SCENARIO
PRODUCTION (Vehicles)

1
2
3
4
5
6

CHECK IF IN ATTENDANCE
Aptiv CONTACTS
TITLE NAME PHONE EMAIL
AQE
SQE
BUYER
PROGRAM MGR
PPAP COORDINATOR
COMPONENT ENGINEER
PRODUCT ENGINEER
RESPONSE TEAM

SUPPLIER CONTACTS
NAME PHONE EMAIL
PRESIDENT
QUALITY MANAGER
KEY CONTACT
PPAP CONTACT
QUALITY CONTACT
RUN@RATE CONTACT

Highlight first column in color to indicate activity requirements.


LEGEND: COMPLETE (Ctrl-g)
OPEN WITH RECOVERY PLAN (Ctrl-y)
NO PLAN OR PLAN DOES NOT MEET PROGRAM TIMING

Product Application Forecast


Does the supplier have working knowledge of the Issues Completion
A following items? Description and/or Sketch Responsibility Date Actio
1 Intended use of product.
2 End use application of product.
3 Latest Prints and Specifications, Traceability
4 Source restrictions specified by engineering.

Design Review
Identify characteristics that will require controls. (KPC's, KCC's, Forecast
CQC's, QCI's)
Ideally, a six sigma capability is the goal. Note gaps Issues Completion
B between desired and actual, with action plans to close. Description and/or Sketch Responsibility Date Actio
Critical dimensions and interfaces of product
1 KPC's, KCC's, CQC's, QCI's, Pass-Through Characteristic/Feature
2 Fit & Function, Safety Compliance
3 Part Packaging Specification
4 Part Labeling requirements

Note: Shipping Container Pkg & Labeling requirements (Suppliers must


comply with requirements. Communicate to suppliers that they should
contact their Aptiv PC&L rep. if they have questions or need assistance.
Information can also be found on the Aptiv Supplier

Forecast
Program Information Completion
C List information required below Details Responsibility Date Actio
1 Platform
2 Model Year
3 Aptiv Estimated Annual Volume
4 Supplier PPAP Due Date
5 Aptiv SOP
6 Aptiv Manufacturing Site
7 Supplier Quoted Tool Capacity (5 days)

Forecast
Product Requirements & Timing Completion
D Record the following if applicable. Details Responsibility Date Actio
1 Prototype requirements.
2 Pre-Production Requirements
3 Other Product Requirements

Supplier Tooling Requirements Forecast


Develop a program review for the tooling supplier on critical Completion
E components. Details Responsibility Date Actio
1 Supplier Tooling Completion Dates
2 Tooling Supplier Name (if different)

Supplier Gage Review Forecast


Mutual Agreement on gage concept proposal. Completion
F Certify Gage to product design record. Details Responsibility Date Actio
1 Development and Approval of Gage Design Plan
2 Gage Evaluation including Measurement System Analysis (MSA)

3 Gaging Completion Dates

Product Measurement Plan Forecast


Have acceptable measurement methods been confirmed and Completion
G correlated? Details Responsibility Date Actio

Has Aptiv received the supplier’s plan for dimensional layout and
measurement of the component? (Should include the measurement
1.1 methods, layout, datums, tools, equipment and fixtures (if applicable)
)

Has engineering reviewed and approved the supplier plan for


1.2 dimensional layout and measurement?

Has the Aptiv Receiving Facility, reviewed and approved the supplier
plan for dimensional layout and measurement?
1.3 (Applicable for sites with a Receiving Inspection)

Not applicable: The supplier has received dimensional accreditation


1.4 by the using division.

Forecast
Capability Assessment Guidelines Completion
H List Characteristic(s)
to be used in capability study. Details Responsibility Date Actio
1.1 KPC / QCI (note details in column)

1.2 KPC / QCI (note details in column)

1.3 KPC / QCI (note details in column)

2 Capability Study Parameters


3 Can your process meet Ppk =/> 1.33? Goal is 2.0
4 Can your process meet Cpk =/> 1.67?

Measurement System Analysis Guidelines Forecast


Add equipment used for Capability Assessment Completion
I and MSA requirements Details Responsibility Date Actio
Measurement Equipment #1
1 & Methodology
Measurement Equipment #2
2 & Methodology
Measurement Equipment #3
3 & Methodology
Measurement Equipment #4
4 & Methodology
Measurement Equipment #5
5 & Methodology

Measurement Equipment #6
6 & Methodology

Forecast
Design Responsible Suppliers Completion
J List all issues/requirements if the supplier is design responsible. Details Responsibility Date Actio
Was a Design Failure Modes & Effects Analysis (DFMEA)
initiated by
1 the supplier?
2 Has the Aptiv PDT reviewed the DFMEA?
Are DFMEA open items addressed on an action plan and
3 communicated to Aptiv's PDT?

Special Process Forecast


For Suppliers and Sub-Suppliers with CQI-9, 11 or 12 requirements, Completion
K complete the following: Audit Completion Date Responsibility Date Actio
1 CQI 9 Heat Treatment assessment is required:
2 CQI 11 Plating assessment is required:
3 CQI 12 Coating assessment is required:
PPAP Guidelines
The link below will take you to the Aptiv
SUPPLIER PPAP SUBMISSION CHECKLIST.
Utilize the Checklist for PPAP discussions.
Forecast
List potential issues below for tracking Completion
L purposes. Details Responsibility Date Actio

Link to SUPPLIER PPAP SUBMISSION REQUIREMENTS


CHECKLIST
(Use attached link or worksheet version provided.) https://Aptiv.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103457.xls
1
2
3
4
5
First Time Quality (FTQ) Improvement Process
Forecast
Completion
M Details Responsibility Date Actio

FTQ Improvement Process Initiation


1 Review Aptiv's FTQ procedure and training presentations as required.
FTQ Improvement Process Documentation
Review the use of Gate Charts / Step Down Charts / Alarm Charts
2 (Appendix 31_2 & 57_3)

Check procedure or methods in place to comprehend FTQ


3 documentation and improvement.
Determine if preliminary data from supplier accurately depicts FTQ
4 results.
Run@Rate Requirements
The link below will take you to the Aptiv R@R Plan. Forecast
Utilize the R@R Plan for discussions. List potential Completion
N issues below for tracking purposes. Details Responsibility Date Actio
Link to Run@Rate Plan
(Use attached link or worksheet version provided.)
Run@Rate Plan https://Aptiv.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xls
Run@Rate Worksheet https://Aptiv.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xls
1
2
3
4
5

WEBSITE INFORMATION Forecast


Determine the suppliers access and working Completion
O knowledge of each Aptiv database below. Details Responsibility Date Actio
1 Capability to access/update the following:
1.1 Supplier Profiles (Discuss Red/Yellow/Green status)

1.2 Supplier Suggestions Program (SSP/SCR)

1.3 Supplier Scorecard (Updated copy if current supplier)

1.4 Problem Solver


1.5 Customer Specific Requirements / Quality Expectations
1.6 Additional Forms & Procedures available on the website
Registered to the Aptiv Supplier Website
2 Mainly used for electronic PPAP submissions
2.1 Initial electronic PPAP submissions
2.2 SSP/SCR required PPAP submissions
New Risk Level of Product(s)
(Determine upon completion of Program Review)

manufacturing, controls a key process or directly affects a key product characteristic. A separate program review
sibility document on RFQ.

plating must comply with the AIAG assessment requirements stated in CQ9, 11 and 12. Including qualified auditors
T MEET PROGRAM TIMING (Ctrl-r)

Actual
Completion
Action Plan Date Progress

Actual
Completion
Action Plan Date Progress

(SQ can note date that this Aptiv PC&L


requirement was reinforced with the
supplier)
.

Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress

Actual
Completion
Action Plan Date Progress

Actual
Completion
Action Plan Date Progress

Actual
Completion
Action Plan Date Progress

Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress

Actual
Completion
Action Plan Date Progress

Actual
Completion
Action Plan Date Progress
Actual
Completion
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Actual
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The following instructions are intended to help the AQE/SQE in performing the Program Review. Take a moment to review the
Instructions. The intent of the program review is to engage the supplier in conversations about various aspects of the current
program/parts and determine areas of concern that will need further action.

The form is protected/locked so that users can tab through fields. To allow attachments (such as program rosters) and/or
and/or additional information into any open field within the form, the form can be unprotected. The password is "unlock".
This will allow each user to customize the program review to fit their needs while continuing to use a common form and process.

We will start the instructions with definitions and acronyms:

KPC Key Product Characteristics


Most important product features or material properties for meeting customer requirements.
The two kinds of KPCs are 1)
safety and compliance, and 2)
fit and function. KPCs may be attributes (present or not)
.
It is required to target variable KPCs at nominal and reduce variation continuously because these characteristics are optimized at the nominal
specification and have a loss function associated with deviating from nominal.

KCC Key Process Control Characteristic


Most important process characteristics that have a direct effect on the KPCs.
Suppliers may designate additional process characteristics as KCCs.

QCI Quality / Customer Interface


A feature or property of a product that is contacted directly by the customer and has an immediate impact on their satisfaction
if not within limits. Or, a characteristic that does not meet the KPC criteria, but is deemed critical to the final product or its manufacturability.

QCC Quality Control Characteristic


Most important process characteristics that have a direct effect on the QCI's. Suppliers may designate additional process characteristics as QCI's.

PPAP Product Part approval process.

Pass-Through Characteristic
Is a characteristic/feature where an anomoly only declares itself under certain conditions such as environmental stimulation and cannot be tested
in Aptiv's operations (i.e. soft tie rods, stepper motor with step loss and steering hose with incorrect rubber component.
The first part of the Program Review is an informational list used by Aptiv and the Supplier for better communication.
Fill in the following information as thoroughly as possible:
Date of Review
Supplier -include both the facility name and parent name where applicable
Supplier Duns Code -this is in reference to the manufacturing site producing the product.
Supplier/Mfg Location
Part Numbers
PPAP Date
Description
Platform
Model Year
SOP Date
Supplier Contacts: -List key supplier contacts
Key Contact
PPAP Contact
Quality Contact
Run@Rate Contact
Aptiv Contacts -List key Aptiv contacts
AQE
SQE
Buyer
Program Manager
PPAP Coordinator
Component Engineer
Product Engineer
Response Team
New Risk Level of Product -Once the review has been completed, evaluate the program risk based on your findings.

Sections A through M are used to track the progress of the supplier through various aspects of building a new product. Each section
focuses on a specific area and is as comprehensive as possible.

The first columns will be used to color code each line item. Green indicates completed, Yellow indicates Open with recovery plan,
Red indicates the suppliers process will not meet Aptiv requirements.
The formatting for these three colors has been automated. Go to the cell you want to change, then hit the following key:
for red use "Ctrl-r" for yellow use "Ctrl-y" for green us "Ctrl-g" this coding will also show up in black/white copies with patterns for each color.
.
The columns represented in each section are used to promote communication between Aptiv and the supplier. It also determines responsibility,
forecasts completion dates, action plans, actual completion dates and progress. Each block is expandable to add information as necessary.

The following gives an explanation of each section:


Section A Product Application Review how the product will be used at Aptiv and the customer, etc.
Section B Design Review Review prints/specs/ QCI/KPC, and pass-through characteristic/feature, packaging and labeling requirements.
Section C Program Information Review with supplier so they understand the final product and it's requirements.
Section D Product Requirements & Timing # of parts required, type of product (saleable vs non-saleable)
to be recorded.
Section E Supplier Tooling Requirements Tooling completion and possible roadblocks should be discussed.
Section F Supplier Gage Review Evaluate and approve gage designs.
Section G Product Measurement Plan Consider the measurement req't and techniques that will be used for dimensional layout on the component prior to ppap.
Section H Capability Assessment Guidelines Determine based on the print requirements, customer requirements. Detail this section well.
Section I Measurement Systems Analysis Guidelines Based on the item listed in section H, detail equipment and methodologies that will be used.
Section J Design Responsible Suppliers If your supplier is responsible for the design, this section should be discussed.
Section K Special Process Evidence of conformance to required CQI assessment required here.
Section L PPAP Guidelines Hyperlink to Aptiv's PPAP checklist
Section M First Time Quality (FTQ)
Improvement Process Training and or evidence of conformance is reviewed in this section.
Section N Run@Rate Requirements Hyperlink to Aptiv's R@R plan
Section O Website Information Lists all websites and programs the supplier will need in working with Aptiv.
labeling requirements.

t on the component prior to ppap.


"Express" Program Review
Section A: Supplier Program Review
Part Number:
Aptiv Information (From Roster Database & Request for Sourcing): Family Parent Part No. (if any):
1 Aptiv Start Of Production Date Prod. Mfg. Loc.:

2 Year:
3 Volume Annual Usage:
4 Information Peak Weekly Usage:

5 Type of Build:
6 Parts required Date:
7
Forecasted Quantity:
8
Builds PML
9 Build when PPAP is required:

10 Supplier PPAP Due Date


11 PPAP Level Required 3
12 Comments

Section B: Supplier Commitments (Supplier complete)


:
13 Supplier First Parts Promise Date
14 Estimated PPAP package delivery
15 Supplier Quoted 5 Day Capacity
(vs. Peak Usage in question #4)

16 The supplier is responsible to register and use the Aptiv Supplier Websites and must be capable to update and access the following:
Supplier Profiles
Supplier Suggestion Program (SSP / SCR)

Problem Solver
Customer Specific Requirements/ Quality Expectations
IMDS system (reportable Chemicals)

17 The Supplier agrees to and understands the following:


1. The only authorization to implement Aptiv engineering changes (including marked up prints)
must be issued by the Aptiv Buyer.
2. No change, of any kind, shall be made in material content, processing methods, testing methods, or location of manufacture without the
prior written approval of Aptiv Corporation.
Agreed by:
Authorized representative Date
18 Supplier Comments/ Concerns:

Section C: Run @ Rate :


19 Is Part Commodity Exempt? Y/N Letter Location:
20 Exemption Calc. (highest # 15 / # 4)
(if less than 40%, may exempt Run @ Rate)

21 Approving Supplier Quality Manager Date:

22 Comments:

For Semiconductors Run at Rate is exempt. To ensure commitments are met a CAPACITY STUDY is required.

"Express" Program Review


SPDP Express Form
Instructions
PRINT IN PORTRAIT MODE
SPDP Express forms should be filled in, transmitted, and stored electronically. For E&S - They should
be stored in T:\PURCHASING\SUPL_DEV\AQE\RISK
l ASSESSMENTS\EXPRESS\"COMMODITY"\"SUPPLIER NAME"\"PART #"
Please use the part number as the first part of the filename and put a zero in front of 9 million part
numbers (to achieve 8 digits and proper sort order by Windows Explorer)
.

The tab key can be used to move to the next available field in the form to enter data. Similarly,
l
shift_tab will move to the previous available field.

For filling in the SPDP Express form:


Section A: Volume Information and Scheduled Builds (lines 1 to 10)
should be filled in by the Product
l Engineer or the Program Team Leader. Line 11 will be filled in by the AQE Analyst.

Section B should be filled in by the Supplier (lines 13 to 18). Enter the Supplier Name in the
l appropriate cell and enter the name and date of the authorized Supplier Representative who is filling in
the form.

Section C should be filled in by the AQE. If the part commodity is exempt (see Express form for
criteria)
, it should be listed in the Commodity Exemption letter signed by the Supplier Quality Manager.
l This is expected to be one letter listing all exempted commodities and stored in one location for
reference by all of Supplier Quality.
APTIV Supplier Quality FMEA SEVERITY RANKINGS
Note #1: Any Failure Mode affecting the Vehicle Assembly Plant MUST be ranked an “8” or higher.
Note #2: Any Failure Mode affecting a Aptiv Plant MUST be ranked “5” or higher.

Select from the categories below, using the highest applicable ranking.

Ranking Effect End Customer Vehicle Assembly Plant Aptiv Plant Supplier Plant
10 Hazardous- Potential failure mode affects Potential failure mode may Potential failure mode may Potential failure mode may
without warning safe vehicle operation and/or cause unsafe condition for cause unsafe condition for cause unsafe condition for
involves noncompliance with plant personnel without plant personnel without plant personnel without
government regulation without warning. warning. warning.
warning.
9 Hazardous-with Potential failure mode affects Potential failure mode may Potential failure mode may Potential failure mode may
warning safe vehicle operation and/or cause unsafe condition for cause unsafe condition for cause unsafe condition for
involves noncompliance with plant personnel with warning. plant personnel with warning. plant personnel with warning.
government regulation with
warning.
8 Very High Vehicle/item inoperable (loss Potential failure mode may Potential failure mode may
of primary function)
; failure cause a spill/major disruption, cause a spill/major disruption
mode may cause customer repair, assembly difficulty, at a Aptiv Plant.
walk home, field return, or rework, or sorting at the
durability issue. Vehicle Assembly Plant
7 High Vehicle/item operable but at a Potential failure mode may
reduced level of performance. cause repair, assembly
Customer very dissatisfied. difficulty, rework, sorting at a
Failure mode may cause See Note #1 Aptiv plant.
vehicle repairs at Dealer.
Includes Noise issues
(squeak/rattle)
.
6 Moderate Vehicle/item operable but Potential failure mode may
comfort/convenience item(s)
)
cause special handling of
inoperable/not performing to See Note #1 components at Aptiv-S.
customer expectation (e.g..
Noise)

5 Low Vehicle/item operable but Potential failure mode may


comfort/convenience item(s)
See Note #1 cause inconvenience to Aptiv
operable at a reduced level of prior to assembly.
performance.
4 Very Low Fit and finish item does not See Note #2
conform. Defect noticed by See Note #1
most customers.
3 Minor Fit and finish item does not See Note #2
conform. Defect noticed by See Note #1
average customers.
2 Very Minor Fit and finish item does not See Note #2
conform. Defect noticed by See Note #1
discriminating customers.
1 None No effect. See Note #1 See Note #2
3 Minor Fit and finish item does not See Note #2
conform. Defect noticed by See Note #1
average customers.
2 Very Minor Fit and finish item does not See Note #2
conform. Defect noticed by See Note #1
discriminating customers.
1 None No effect. See Note #1 See Note #2
APTIV Supplier Quality FMEA OCCURRENCE EVALUATION RANKINGS
Sample calculation to determine Ppk value from a likely failure rate of 5 per thousand pieces (see FMEA third Appendix I).

Probability Likely Failure Rates Ppk Ranking

Very High: Persistent Failures


100 per thousand pieces < 0.55 10

50 per thousand pieces > 0.55 9

High: Frequent Failures


20 per thousand pieces > 0.78 8

> 0.86
10 per thousand pieces 7

Moderate: Occasional Failures 5 per thousand pieces > 0.94 6

2 per thousand pieces >1.00 5

1 per thousand pieces >1.10 4

Low: Relatively Few Failures


0.5 per thousand pieces >1.20 3

0.1 per thousand pieces > 1.30 2

Remote: Failure is unlikely


< 0.001 per thousand pieces * > 1.67 1
Note: Identical to Manual except for Ranking of 1. Manual allows for .01 per thousand (10 PPM)

APTIV Supplier Quality FMEA Detection Rankings


Ranking Effect PFMEA

10 Absolute Uncertainty Cannot detect or is not checked.

9 Very Remote Control is achieved with indirect or random checks only.

8 Remote Control is achieved with visual inspection only.

7 Very Low Control is achieved with double visual inspection only.

6 Low Control is achieved with charting methods, such as SPC


(Statistical Process Control)
OR gauging performed on setup and
first-piece check. *

5 Moderate Control is based on variable or attribute gauging performed 100%


of the parts after parts have left the station.

4 Moderately High Error detection in subsequent operation. *

3 High Error detection in-station, or error detection in subsequent


operations by multiple layers of acceptance: supply, select,
install, verify. Cannot accept discrepant part.

2 Very High Error detection in-station (automatic gauging with automatic stop
feature)
. Cannot pass discrepant part.

1 Almost Certain Discrepant parts cannot be made because item has been error-
proofed by process/product design.

* Note: Identical to Manual except for Rankings of 6 and 4. Words “OR gauging performed on setup and first piece check”
moved from a detection of 4 to a detection of 6