Supply Chain

Management Group

Supplier APQP Training

Advanced Product Quality Planning

GOAL : FLAWLESS LAUNCH !

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 Supplier APQP Overview Supply Chain
Mgmt Group

APQP is:
A structured method for defining & executing the
actions necessary to ensures a product satisfies
the customer.
 Supplier Led
 Required
of all designated component
manufacturing.
 Maximize the opportunity to achieve a defect free
product launch and beyond.

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 Supplier APQP Overview Supply Chain
Mgmt Group

Scope: To define the process through the

sourcing decision of a new or modified
product by a Supplier to Dana to the
approval of the PPAP.
Reasons for APQP –
 Cost Avoidance – Scrap, Engineering Changes
 Robust Products – Durable / Reliable
 Robust Processes – Stable / Capable
 Clearlydefined & understood launch
requirements
 Builds solid Supplier relations
 Synergy
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 Dana Supplier Quality Manual Supply Chain
Mgmt Group

5. Supplier Advance Product Quality

Planning (APQP)
 Suppliers are required to conform to the latest
edition of the AIAG Advance Product Quality
Planning Manual, located at http://www.aiag.org,
for the introduction of a new or significantly
modified production product to Dana.

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 Supplier APQP Supply Chain
Mgmt Group

 APQP Required
 Program Launches & Select Resourcing Actions
 Supplier Responsible for complete APQP
• Supplier Development Engineer validates all APQP Elements
through documentation and objective evidence submitted in
the APQP Workbook.
• Supplier Development on-site review only occurs for
suppliers who consistently fail to submit objective evidence
to the APQP timeline and/or at risk suppliers as identified by
the Program Team

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 Supplier APQP Status Report Supply Chain
Mgmt Group

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 Supply Chain
Mgmt Group

 In order to initiate APQP Activity with a Supplier the following is

required –
 Date the Dana LOI or Purchase Order Was issued
 Date The Dana Tooling Order was or will be issued.
 Prototype Sample quantities and timing.
 Requested PPAP Date

 WITHOUT THIS INFORMATION SUPPLIER DEVELOPMENT CANNOT

INITIATE THE APQP ACTIVITY.

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 Supply Chain
Management Group

Supplier APQP Elements

What is the requirement?

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 Supplier APQP Status Report Elements Supply Chain
Mgmt Group

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 Supplier APQP Status Report Elements Supply Chain
Mgmt Group

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 Supplier APQP Status Report Elements Supply Chain
Mgmt Group

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 Supplier APQP Status Report Elements Supply Chain
Mgmt Group

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 Supplier APQP Status Report Elements Supply Chain
Mgmt Group

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 Supplier APQP Status Report Elements Supply Chain
Mgmt Group

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 Supplier APQP Status Report Elements Supply Chain
Mgmt Group

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 Supply Chain
Management Group

Supplier APQP Status Report Elements

What are we looking for as Objective Evidence

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 Objective Evidence Required – Elements 1 - 3 Supply Chain
Mgmt Group

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 Objective Evidence Required – Elements 4 - 7 Supply Chain
Mgmt Group

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 Objective Evidence Required – Elements 8 - 10 Supply Chain
Mgmt Group

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 Prototype Sample Inspection Requirements Supply Chain
Mgmt Group

All prototype samples furnished by suppliers shall conform to the following

requirements for their applicable Dana Product Group.
Commercial Vehicle & Light Vehicle Driveline Technologies - Each part is to be
serialized on a non critical surface (consult with the applicable Engineering
Group for non critical surface identification). The preferred identification is Part
Number and Consecutive Dash Number. (Example: Part Number -1, -2, etc....).

An inspection report is to be furnished for each serialized part for all

critical/significant dimensions as designated on either the Dana Drawing or
Engineering Specification.

At minimum, the inspection report shall include - date inspected, Inspector's

signature, part & serial dash number, revision level, part name, purchase order
number, part dimension/tolerance/actual dimension & the Gage R&R reports for
all inspection tools utilized( for CMM submit a copy of the current Calibration
Certificate).

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 Prototype Sample Inspection Requirements Supply Chain
Mgmt Group

The inspection report shall be in pdf file format and named with the Dana
Program, Part Number and Date. (Example: Program Name_Part Number_ Month-
Day-Year.pdf).

The inspection report shall be shipped with the prototype samples. Prototype
samples received without the accompanying inspection report will be rejected.

Any Metallurgical/Heat Treat/Physical Test results available for the prototype parts
should be included with the inspection report furnished.
Any additional inspection requirements, outside of that listed above, will be
delineated on the prototype quote request and listed on the prototype purchase
order.

In all cases prototype samples that do not conform to the Dana Drawing and/or
Specifications shall not be shipped prior to receipt of an approved Engineering
Change or Deviation. A copy of the approval document shall be included with the
prototype part shipment.

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Objective Evidence Required – Elements11 - 12 Supply Chain
Mgmt Group

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Objective Evidence Required – Elements 13 - 15 Supply Chain
Mgmt Group

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Objective Evidence Required – Elements 16 - 19 Supply Chain
Mgmt Group

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 Objective Evidence Required – Elements 20 - 23 Supply Chain
Mgmt Group

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 Additional Dana PPAP Requirements Supply Chain
Mgmt Group

Dana Facilities, receiving previously PPAP approved carryover parts, have the right to request a new PPAP
submission (default Level 3) when the initial PPAP approval, evidenced by a signed PSW, is dated back 1 year or
older. The supplier furnishing the carryover part will be advised when this requirement applies by the respective Dana
Facility.

Suppliers furnishing parts being PPAP’d for the first time and shipped to multiple Dana Facilities shall submit the
complete Level 3 PPAP to the Dana Facility designated on their Purchase Order. For the remainder of the Dana ship
to points they shall provide an approved copy of the PSW prior to shipping any production parts.

Suppliers desiring to ship the same part number from multiple manufacturing sites must obtain the approval of the
Dana Receiving Facility, Dana Engineering and Dana’s end customer where applicable.

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 Safe Launch Supply Chain
Mgmt Group

The purpose of the Safe Launch Plan is to protect Dana Facilities from
receiving quality non-conformances during critical new product launch
periods and validate the supplier's Production Control Plan during
volume production runs. It is in addition to all normal process inspections
and evaluations outlined in the Production Control Plan and is a post
processing, off-line, separate and independent from the normal
manufacturing process check. Use of any in process
inspection/containment stations requires the prior approval of Dana.

The Safe Launch Plan shall be in effect for a minimum of 90 days or the
first 5 supplier production runs, whichever is longer, from the start of
PPAP Approved part shipments to the receiving Dana facility. If any
discrepant parts are received by a Dana facility during the Safe Launch
period it shall be extended for a timeframe to be determined by the
receiving Dana facility.

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 Safe Launch Supply Chain
Mgmt Group

Any non-conformances discovered at a Dana facility during the Safe

Launch period require immediate and irreversible corrective action
within 72 hours of notification. In addition, any non-conformances
discovered at a Dana facility requires supplier, or supplier designated,
representation on site at the Dana facility to initiate sorting and
containment actions, back through their organization, within 24 hours.

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 Safe Launch Supply Chain
Mgmt Group

The Safe Launch Plan shall include 100% evaluation of --

All Dana designated Critical and/or Significant Characteristics

(Variable)

All Customer attachment( pass through) characteristics identified by Dana

Engineering (Attribute)

All Significant Characteristics to the process identified by the supplier

(Variable)

Verification that the packaging and labeling conforms to the Supplier

Packaging Specification form approved by the receiving Dana facility.
(Attribute)

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 Safe Launch Supply Chain
Mgmt Group

Data from safe launch inspections shall be forwarded to both the Dana Receiving
Plant & SupplierDevelopment@dana.com, for each production lot shipped, so it is
received prior to the production lot.

Product shipped to Dana that has been evaluated in the Safe Launch process shall
be identified by means of a Green Sticker, attached to every individual carton,
signed by the person accountable to perform this function.

Failure to implement a robust Safe Launch Process, containing these requirements

as a minimum, will result in a Supplier being placed on Restricted Shipping 2 and
other possible consequences.

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 Customer Attachment Points Supply Chain
Mgmt Group

Customer Attachment Points:

Customer Attachment Points will be communicated to suppliers by

designation, ( <CAP> ), on Dana Product Drawings.

Customer Attachment Points require Poke-A-Yoke at the source of

manufacture.

If Poke-A-Yoke cannot be achieved an alternative control plan method

must be proposed by the supplier and be approved by Dana.

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 Supply Chain
Mgmt Group

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