CHOPRA INDUSTRIES (P) LTD.

–UNIT-IV
QUALITY MANAGEMENT SYSTEM PROCEDURE Procedure No.: P-ENG-01
Advanced Product Quality Planning Page 1 of 5

-Resources Competence, Requirement

* New Machine, Tools, IMT, if Person Competence
identified during development.
* New Raw material, if identified General * Knowledge of all
during development.. Manager Product, Process
and Quality
system
CFT * Knowledge of
Member product, process
and quality
system related to
their area.

Advanced Product Quality

Input
* Customer enquiry for product.
* Product specifications.
* Purchase Order
* Customer specification /National-
International standrad /specification
of product.
* Customer’s specific requirement.
* Data from existing product and
process.
*Existing Process flow diagram,
Process FMEAs, Control plan,
Process instructions, packing
standard, inspection standards etc.
* List of existing Machine, Tools,
IMT, Product etc.
* Phasewise Inputs are given on next
page before Activity Description.
Output
Planning
Objective: Carryout planning * Feasibility Study Report.
and execution of various ** Timing plan for execution of
activities.
activities during the product
development as to ensure that * Sign-Off Report.
all the requirements and needs * PPAP of product.
of customer are met. * Developed product.
Scope: This process covers all
new product as well as changed
product.
Process Owner: GM and CFT

Method Controls Monitoring/Measurement

* Receive enquiry and review for * Feasibility review before Description Acceptance
business opportunity. development. criteria
* Nominate a CFT & carryout * Review/check of availability for APQP All new
feasibility study. latest standard /Specification. consideration. product
* Prepare APQP scope. * Receiving of contract commitment /changed
* Prepare timing plan for all before development or consideration product must
identified activities as per scope. of business opportunity before cover all
* Execute all activities as per development without contract. stages of
target. * Review and development done by APQP.
* Carryout inspection & testing of CFT (Cross Functional Team).
product.
* Carry out Initial process
capability and MSA study.
* Compile all input and prepare
PPAP file and submit to customer,
Whenever customer requirement.
* Prepare summary sign off and
send to customer.
Detailed activities are given at sr.
no. 2 (Activity Description)

Rev. No.: 00
Prepared By: Approved By: Rev. Date: 20.05.2013
 CHOPRA INDUSTRIES (P) LTD.–UNIT-IV
QUALITY MANAGEMENT SYSTEM PROCEDURE Procedure No.: P-ENG-01
Advanced Product Quality Planning Page 2 of 5

APQP (Input and Output for Different Phases)

Product Design & Processes (Design Product & Process Feedback

Planning Development &Development) Validation Assessment &
Actions
* Customer * Contract Review * Process Flow * Inspection & Testing * Corrective actions
Specification * New Machines & Diagram results. * Continual
* Data from accessories * Process FMEA * MSA results Improvement.
exiting product & requirement * Pre-launch Control * Preliminary process
process * Product Plan capability study results.
* Customer development plan. * Process Instructions * PPAP
Enquiry * New Instruments, * Special * Production Control
*National Gauges facilities Characteristics plan.
/International requirement * Inspection and
standards Packing standards
* Feasibility * MSA plan.
Study * Preliminary Process
capability study plan.

2.0 Activity Description :

S.No. Activity Responsibility Ref. Document

PLANNING
1 Receive / or generate the enquiry for development General Manager Customer Enquiry
of new product.
2 Identify new product for development based on the MD / General Business Plan
business available & incorporate in business plan. Manager
3 Considering the requirements of customer inquiry MR
or product development plans mentioned in the
business plan collect /compile.
* Inputs such as customer specifications
references received along with the enquiry or
mentioned in the inquiry.
* Standards, specifications other performance
/measurement details related to product.
4 Nominate a cross functional team to study, plan General Manager F-ENG-01-19
and execute the product development activities
and define the scope of development planning.

PRODUCT & PROCESS DESIGN AND DEVELOPMENT

NOTE: The company adopt the specification of customer or established nationally/internationally by
Standard bodies or such organizations. During the feasibility study it is reviewed that company is
capable to meet these requirements.
5 Review the product requirements specified by the CFT Customer Specs. or
customer or mentioned in the standard. relevant standards
6 Carry out the feasibility study. If some clarification -do-
is required obtain the same from customer or
establish by referring relevant standard,
specification and other literature.
7 Prepare a team feasibility commitment report -do- F-ENG-01-01

Rev. No.: 00
Prepared By: Approved By: Rev. Date: 20.05.2013
 CHOPRA INDUSTRIES (P) LTD.–UNIT-IV
QUALITY MANAGEMENT SYSTEM PROCEDURE Procedure No.: P-ENG-01
Advanced Product Quality Planning Page 3 of 5

S.No. Activity Responsibility Ref. Document

8 Carry out the contract review with the customer, if Managing Director F-MKT-01-01
product is feasible to manufacture with some
changes / by addition of some machine, equipment
or other facility.
9 If the product manufacturing/supply is not feasible General Manager Letter
send a regret letter to the customer
10 Follow up with the customer to get purchasing -do- PO/Email/Saving
commitment (when the product development is
considered against an enquiry). Not required from
existing customer
11 After receipt of purchasing commitment from the -do-
customer intimate CFT to initiate the planning and
execution of product development activities
NOTE: Normally customer’s specific product development is started after receipt of purchasing
Commitment from the customer. However keeping in view the business relationship with the existing
customer, business volumes & development cost involved the development activities may be initiated
before receipt of formal purchasing commitment with the approval of MD.
12 Prepare a list detailing the machine, tools, CFT F-ENG-01-03
material and other accessories required to
manufacture the product.
13 Prepare the plan for development of product -do- F-ENG-01-04
related document tooling equipment, material
and other accessories.
14 Prepare the following documents as required. -do-
* Process Flow Diagram.
* Process Failure mode and effect analysis.
* Pre launch control plan
* Process instructions.
* Incoming, in-process and final inspection.
* Packaging specifications and standard
15 Organize to develop and procure new tooling General Manager
facilities & material (raw material) for product
manufacturing.
16 Prepare plan for assessment of measurement Head (QA) F-ENG-01-13
system capability for all new type of
measurement system.
17 Plan for the assessment of preliminary process -do- F-ENG-01-14
capability of product and process characteristics
covering at least all special characteristics
identified by the customer or through FMEA, If
not established earlier.
18 Review the availability of all documents, General Manager
material, tooling, machines / equipment and
plan the date for trial production run along with
the CFT.
19 Carry out the Product and process validation, All section
trail production as per the plan. Incharges
20 Assess the product / process preliminary Head (QA) F-ENG-01-14
capability during the trial run as planned.

Rev. No.: 00
Prepared By: Approved By: Rev. Date: 20.05.2013
 CHOPRA INDUSTRIES (P) LTD.–UNIT-IV
QUALITY MANAGEMENT SYSTEM PROCEDURE Procedure No.: P-ENG-01
Advanced Product Quality Planning Page 4 of 5

S.No. Activity Responsibility Ref. Document

21 Carry out the measurement system analysis for the Head (QA) P-QAD-04
new measurement system and or measurement
system used for SPC data collection.
22 Arrange to check all the product characteristics as -do- P-QAD-01
specified in relevant inspection standard.
23 Pack the product as per packing /packaging Despatch Incharge F-PRD-03-01
standard / specifications.
24 Dispatch the product to customer under the Dispatch Incharge P-PRD-03
instruction of Plant head
25 Compile the records, document, collect the product Head (QA) P-ENG-02
sample and submit the PPAP.
26 Follow up with customer to get the PPAP approval. -do-
27 Receive the PPAP evaluation / approval from the -do-
customer.
28 Review the PPAP evaluation with the CFT. -do-

29 In case customer desires some changes in product CFT & P-ENG-02

or document, carryout the same and re submit the Head (QA)
PPAP.
30 Once the PPAP approval is granted by the Head (QA)
customer, review the following.
* Process Flow Chart.
* Process FMEA.
* Pre Launch Control Plan.
31 If Any Engineering change received then review the Development Head ECN Note
same & fill up on the engineering change format
32 Inform to all the departments with signing on
engineering change format
33 Update all the documents as per ECN
34 Update all the document and finalized production CFT Control plan
control plan.
35 Prepare “Quality planning Sign off” and intimate to -do- F-ENG-01-11
the management.
36 Inform Head (PPC) to plan the regular production of General Manager
product as per the requirement.
Feedback Assessment and Corrective actions
37 Follow up relevant procedure for performing All concerned
various activities during regular production.
38 Continuously improve product, process, delivery, -do- P-SYS-11
and service to enhance customer satisfaction

3.0 References:
P-MKT-01 Procedure for Management of Customer related Process
P-SYS-02 Procedure for Control of Documents.
P-ENG-02 Procedure for Product Part Approval Process.

Rev. No.: 00
Prepared By: Approved By: Rev. Date: 20.05.2013
 CHOPRA INDUSTRIES (P) LTD.–UNIT-IV
QUALITY MANAGEMENT SYSTEM PROCEDURE Procedure No.: P-ENG-01
Advanced Product Quality Planning Page 5 of 5

P-TRM-01 Procedure for Management of Production Tooling

P-SYS-04 Procedure for Continual Improvement & Analysis of data
P-PUR-01 Procedure for Purchasing, Selection, Approval and Evaluation of Suppliers.
P-QAD-04 Procedure for Measurement System Analysis.
P-PRD-03 Procedure for Packing, Labeling and Dispatch
P-QAD-01 Procedure for Monitoring & Measuring Of Product and Layout & Functional Testing
P-QAD-02 Procedure for Laboratory Management.

4.0 Records:

F-ENG-01-01 Team Feasibility Commitment

F-ENG-01-02 Feasibility Study Report Phase-1
F-ENG-01-03 Check list New Equipment, Tooling & Test equipment
F-ENG-01-04 APQP Timing Chart
F-ENG-01-05 Floor Plan Check List
F-ENG-01-06 Process Flow Check List
F-ENG-01-07 FMEA Check List
F-ENG-01-08 Control Plan Check List
F-ENG-01-09 Product /Process Quality Check List
F-ENG-01-10 Operation Standard
F-ENG-01-11 Product Quality Planning Sign Off
F-ENG-01-12 List of Special Characteristics
F-ENG-01-13 MSA Plan
F-ENG-01-14 Process Capability Plan
F-ENG-01-15 Process Flow Diagram
F-ENG-01-16 Feasibility Phase-II
F-ENG-01-17 Process FMEA
F-ENG-01-18 Engineering Change Note
F-EG-01-01 Control Plan
F-PRD-03-01 Packing Standards

F-ENG-01-19 CFT Teams

F-ENG-01-20 Master List of Drawings

Rev. No.: 00
Prepared By: Approved By: Rev. Date: 20.05.2013