WHAT IS APQP AND HOW MAKE THE APQP PROCEDURE

1. S l. No.	WHAT IS APQP IN AUTOMOTIVE QUALITY AND HOW MANY PHASE IN APQP  Activity			Input	Output	Responsibility
   1 2 3 4 5 6 7 8 9	PHASE – I Received Part Drawing / Standard from Customer end. After received part drawing & standard review of customer inputs & material specification. Product Manufacturing review meeting If required, cost negotiation and spec. meeting (if necessary) shall be done with the customer for the same and Receive LOI / Purchase Order to Customer and go ahead for development department. Product manufacturing timing planning review meeting (APQP Plan) Prepare Bill of material If Initial Feasibility & Risk Analysis Feasible prepares Quotation, discuss and take approval from top management and send to customer Prepare Development Time line Plan with clearly defined responsibility of CFT Team and target date. (Also prepare the micro plan for each activity item of time line plan with defined activity review frequency) and also prepare the responsibility matrix. At the time of Development time line preparation, it shall be ensured that all the past problem related to similar product has been taken care. If LOI & Purchase Order is Feasible, Review of Phase – I Activities. Phase – I Activities feedback give to Plant Head and review required within two weeks.			Part drawing / standard / Samples Part Drawing / Standard LOI & Purchase Order APQP time plan BOM List of Critical Characteristic& Drawings, CSR  MOM & PFD Project Review record LOI & Purchase Order	Review of Customer Input List of Critical Characteristic. Go to Dev. Dept. Time management Go to dev. Dept. Feasibility & Risk Analysis Go to all dept. Past Problem review record Review of Phase – I Activity (MOM)	Head Engg. Head Engg. Head Engg. Head Engg. Head Engg. Head Engg. Head Engg. Page 02 of 07 Head Engg.
   10 11 12 13 14	PHASE – II& PHASE – III (Product & Process Design and Development. Prepare Development Time line Plan with clearly defined responsibility of CFT Team and target date and also prepare the responsibility matrix. Responsibility Matrix shall explain the Cross Function team as below. CFT Members:-Mkt, Engg., Dev, QA, Production, Store, Purchase, Dispatch, Tool room. Development plan Activity Review Frequency shall be once in a week by CFT and once in month by top management or customer specific. Responsibility Matrix shall contain the below (Micro plan activity) activities during preparation of time line plan. a)       TOOL & FIXTURE PREPARATION b)       EQUIPMENT / MACHINE PREPARATION  c)        GAUGE \ INSP EQPT. PREPARATION  d)       ADVANCE DESIGN CHANGE INFORMATION e)        PAST TROUBLE, RE-OCCUR PREVENTION VERIFICATION f)        SPEC TEST VERIFICATION PLAN g)       CTQ PARAMETERS IDENTIFICATON h)       MAKING PROCESS FLOW CHART i)         PROCESS FMEA VERIFICATION PLAN j)        MAKING PRE-LAUNCH CONTROL PLAN k)       TIER 3 READYNESS l)         LOCAL/IMPORTED RAW MATERIAL PLAN m)     PACKAGING TRIAL PLAN n)       CAPACITY VERIFICATION PLAN   o)       FLOOR PLAN LAYOUT p)       CHARACTERISTICS MATRIX q)       PRELIMINAY PROCESS CAPABILITY STUDY PLAN r)        MEASUREMENT SYSTEM ANALYSIS PALN Prepare Listing of Jig, Fixtures, Gauges, Equipment, and Machines Tools. Prepare B.O.P & Part Drawing (If Required), and get Approval if required. Prepare Operator training plan Prepare sample submission to customer timing plan for 4 phases: PP trial, MPT, Pilot trial and SOP			Feasibility Study, Risk Analysis, Contract Review & LOI & Tool Go, Purchase Order, CSR Prelaunch Control Plan, FMEA, OPS, Inspection Standard Development Plan Approved Customer input BOM, Drawings Training plan Submission report	Development Plan Responsibility Matrix with CFT Team, Micro plan, Project Review record. Production Control plan, Capacity confirmation, SPC, MSA, Spec Test Results, Layout inspection List of Jig, Fixture, Gauge, Equipment, Machines & Tools BOM, Drawings Trained operators Page 03 of 07 Inspection report	Dev Head Head Dev Head Dev. Head Dev. Head Dev.
   12 13 14 15 16 17 18	PHASE – IV (Product and process Validation) Conduct Significant Product run (Parts / 8 Hrs) or Customer specific (Capacity Confirmation) Conduct Cpk & MSA Study and Process Qualification (If Required) Conduct internal & External packaging evaluation Prepare the production control plan Confirm the PFMEA implementation results Confirm the Spec Test Results Conduct Layout inspection for 05 Samples or Customer Specific. PSW Submission to Customer with PPAP Level III or Customer Specific requirement. If Completion Ok, then release Control Plan, S.O.P, FMEA for Production process. If Completion is not ok, then re-Start Ram pup Activities (Review of targets & Monitoring of Process Stability) After PSW Sign off with the customer, Start Ramp up Activities (Review of targets & Monitoring of Process Stability) And Conduct the review of quality management system. Production part approval by customer Prepare production control plan, refer the procedure of control plan QSP:33 Prepare Quality Planning sign-off and Management support			1 of 12 Production Control plan, Capacity confirmation, SPC, MSA, Spec Test Results, Layout inspection Level III PPAP or as per customer requirement All targets All targets Level III PPAP or as per customer requirement, Status of initial supply record Inspection report Control plan Quality inspection report	Level III PPAP or as per customer requirement Signed PSW Monitoring Monitoring APQP Check list APQP Sign off SOP Quality review Quality Management System Review check sheet Page 04 of 07	Production& NPD NPD NPD NPD QA & QMS Head Dev, QA & Production Head Engg.
   Sl. No.	Activity			Input	Output	Responsibility
   20 21   22 22 23  24	PHASE - V Get feedback from customer / communicate to customer for further action. Initial control period initiation. Monitor production, defect and dispatch Review learning of Project & Review of Phase – V Activities. Phase – V Activities feedback give to Plant Head and review required within two weeks. APQP project file has been completed as per the checklist & signoff APQP file document has been reviewed once in a year or when any customer complaint / major process issue has been noticed.			Feedback report Control plan, SPC Plan & SOP Monitoring All targets Completion Results APQP file Quality issue	Action Plan Control Plan & S.O.P Production Smooth part production Monitoring Future reference Smooth part production	NPD NPD CFT with Plant Head. Head Engg. HeadEngg. CFT with Plant Head. Page 05 of 07
   1 of 12 5.         Reference Procedure:- 5.1 Initial Supply Control, 5.2 Change Management, 5.3 Control of Documents, 5.4 Control of Records, 5.5 Control of NCR, 5.6 Supplier Quality Assurance,5.7 Tooling management, 5.8 Production Part Approval process, 5.9 failure mode & effects analysis, 5.10 Identification &traceability, 5.11 4 M change control, 5.12 corrective & preventive action Page 06 of 07 6.        Formats:- 6.1 PPAP COVER PAGE F/ENGG/01 6.2 APQP/Part Development Timing plan  F-DEV-01 6.3 Customer Drawing Review Sheet F-DEV-02 6.4 IPC Sign Off    F-DEV-03 6.5 Team Feasibility F-DEV-04 6.6 Process Flow Diagram F-Dev-05 6.7 PFMEA F-DEV-06 6.8 Control Plan F-DEV-07 6.9 List of Tooling F-DEV-08 7.0 Product Quality Sign off F-DEV-09 7.1 Part Submission Warrant F-DEV-10 7.2 Cross Functional Team F-DEV-11 7.3 Raw Material Test Planning F-DEV-12 7.4 Packaging Standard F-DEV-13a 7.5 Things Going Right Things Gone Wrong F-DEV-13 7.6 List of Development Items F-DEV-14 7.7 FMEA Review Plan F-DEV-15 7.8 Contract Review Check Sheet F-DEV-16 7.9 Part Development History Sheet F-DEV-17 8.0 APQP Meeting F-DEV-18 8.1 Checking Aids F-DEV-19 8.2 Engineering Change Request F-DEV-20 8.3 Risk Analysis F-DEV-21 8.4 Operator Contingency Plan F-DEV-22 8.5 ECN Tracking Sheet F-DEV-23 8.6 APQP Matrix F-DEV-24 8.7 Tool Development Plan F-DEV-25 8.8 List OF DEFECTS Unable TO Capture F-DEV-26 8.9 Bill of Material F-DEV-27 9.0 PPK/CP PLAN & REPORT F-DEV-28 9.1 List of Poka Yoke 7.0       ISO/TS 16949 Clause Reference Number  : 7.2.1, 7.2.2, 7.2.3, 7.3.2.2, 7.3.2.3, 7.3.3.
   01		16.12.2017	Changes done as per ISO/TS 16949 : 2009 Standard
   Rev No.		Date	Details of Amendment

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