Doc.
No BI/QSP/05
APQP PROCEDURE Rev: 3
Rev. Date 04.01.2020
1 Purpose
To Establish a Documented Procedure for developing a new Product by Ensuring that all customer requirements are
1.1
met & incorporated in the Part developed and in the process adopted to manufacture the part.
2 Scope
2.1 Applicable to all Automotive NPD Parts & ECN parts ( Based on customer requirements only)
3 Responsibility
3.1 NPD Dept. & CFT
4 Procedure
Before Start the APQP Activity,understand the Customer Drawing,Customer specific requirements & Part specific
requirements / standards & Other safety requirements ( If any ).
4.1 PHASE I - Plan & Define the program
The following activities has to be done in Phase I
1. Understanding Voice of the customer ( CSR ) (QMP 7.5.1.1 D/A)
2.Formation of Team & Defining the Roles & Responsibilities to the Team Member based on the competency level. (
BI/LIST/CFT)
3. Conduct the feasibility study.
4. Goals for productivity & Quality should be defined during planning
5.Experience from Previous Developments ( TGR & TGW ) should be considered.( BI/NPD/TGW & BI/NPD/TGR) &
Conduct feasibility review.
6.Review of similar part In-house rejections / customer complaints.
7. Product / Process Bench mark data should be considered during planning.
8. Review of Resource requirements such as New machines , Instruments, Competent Man power.
9. Management review meeting & management support.( QMP 9.3 R /B )
4.2 PHASE II – PRODUCT DESIGN & DEVELOPMENT
The following activities has to be done in Phase – II
Since all products are manufactured according to customer drawings, specifications and requirements, no product
design and developments involved. Hence this Phase is excluded from the scope & the following limited activities has
to be done in phase-II
1. Identification of the Significant product characteristics.(QMP 8.3.3.3 R/A)
2 .Review of drawing requirements including material specification & traceability (labelling ) requirements.
3. Prepare the preliminary process flow chart. (QMP 8.3.5 D/A)
4. Prepare the stage drawings according to Pre Process flow. (QMP 8.3.5 D/G)
5. Review of tools,Fixtures,Poka-yoke, gauges, Trays & test equipment requirements & Procurement plan.
6.Review of external process such as plating , heat treatment , wire cutting...,
7. Identification & approval of external suppliers & Procurement activity ( Enquiry to receipt) .
8. Establish the fixture, gauge, equipment Verification & validation plan.
9. Establish the Part verification & validation plan.
10. Management review meeting & management support.
4.3 PHASE III – PROCESS DESIGN & DEVELOPMENT
The following activities has to be done in Phase - III
1.Final process flow diagram.
2. Process / Product characteristics matrix & it’s control.
3. Process failure mode and effective analysis ( PFMEA).
4. Pre-launch Control plan.
5.Preparation of machine program & Shop floor layout.
6.Capacity planning.
7.Product specific Work instructions / SOP’s
8.Packing specifications & packing standards.
9.Define the gauge calibration / fixture , PY verification & validation frequency.
10.Equipment maintenance plan & frequency.
11.Establish the sampling plan.
12.Identification of statistical tools.
13.Preliminary process capability study plan.
14.Measurement system analysis study plan.
15. Management review meeting & management support.
4.4 PHASE IV – PRODUCT & PROCESS VALIDATION
The following activities has to be done in Phase – IV
1. Preparation of Production control plan & PFD.
2.sample parts development & approval from customer.
3. Conduct the Production trail run & set the production, quality goals.
4. Perform the Production Part Approval Process including sub supplier PPAP.
5. Evaluation of packing methods / standards.
6. Conduct the measurement system analysis study.
7. Conduct the preliminary process capability study.
8. Submit the Pilot lot to customer & get feedback from customer.
9. Quality planning sign-off.
10. Management review meeting & management support.
4.5 PHASE V – FEEDBACK , ASSESSMENT & CORRECTIVE ACTION
The following activities has to be done in Phase – V
1.Receive & analyse the Feedback of first batch from customer
2.Conduct the Customer satisfaction survey & analyse the result,take the necessary action to improve.
3. Record the TGW / TGR status of the project.
4.Reduce the variation by continuous actions for the issues ( Internal / external ).
5. Handover to serial production.
6.Identify the continual improvement projects for improvement.
7. Management review meeting & management support.
Documents & Record Reference : Annexture
* Any changes happens Including delays during APQP activity at any phase ,it should be communicated to
Note:
Customer / in house on time.
PREPARED BY: MR APPROVED BY: CEO
