Defining The Advanced Product Quality Planning Information Technology Essay

Advanced Product Quality Planning (APQP) is a structured method for defining and executing the actions necessary to ensure a product satisfies the customer along with cost and time. APQP is required of all vehicle, system, subsystem and component manufacturing locations.

1.2 Goal

The goal of APQP is to facilitate communication with all persons involved in a programme and ensure that all required steps are completed on time, at acceptable cost and quality levels.

1.3 Purpose

The purpose of this guideline is to establish:

Common APQP expectations for all M&M activities.

Common APQP process metrics.

Common APQP deliverables.

A common programme status-reporting format.

Lead and Support roles and responsibilities for each APQP Element.

1.4 Approach

APQP emphasise on Up-front planning, First three part of the P-D-C-A cycle are devoted to up-front product quality planning through product / Process Validation. The Act of implementation, the fourth part is the stage where the importance of evaluating the output serves two functions; to determine if customers are satisfied, and to support the pursuit of continuous improvement.

This guideline focuses on 23 key APQP elements. Definitions, expectations, and deliverables for these elements are identified in Section 5.0 APQP Element Description of this guideline. The status for these disciplines is summarized on the APQP Status Report. This guideline provides a management tool for follow-up and timely completion of all 23 APQP Elements.

1.5 Applicability

APQP status reporting is a requirement of all M&M activities and must be applied to the following:

New Product launch/ relaunch.

Changed/ modified product launch.

Launch of a new manufacturing site.

Significant process changes (new facilities/ toolings).

High impact suppliers.

Carry over issues.

Part Submission Warrant (PSW) requirement as per the MQS Mahindra Production Part Approval Process Manual.

2.0 APQP Fundamentals

2.1 Teams

The first step in the Advanced Product Quality Planning Process is to assign lead responsibility for every APQP Element. This leader establishes a cross-functional team to complete the element requirements on time. Effective Product Quality Planning requires a cross-functional team including representatives from Product Development, Manufacturing Engineering, Manufacturing Plants, Purchasing, Quality, Field Service, Sales, Suppliers, and Customers, as appropriate.

2.2 Elements

This guideline focuses on 23 Key APQP disciplines, identified as APQP elements. These elements, when summarized and reported, communicate the quality planning status of a programme.

2.3 Adjustments

If the programme is considered to be low risk, the APQP leader may skip certain APQP elements. For example, if the product is carry-over with minor changes, existing control plans can be used and/ or packaging evaluations may not be required. The cross-functional team must agree to all deviations from the APQP process. If the team agrees that an element is not required, the function should write “N/A” for “not applicable” in the remarks section of the APQP Status Report (Annexure 1).

2.4 Roles & Responsibilities

The APQP Lead/Support Responsibilities are documented in Section 5.0 APQP Element Description, of this guideline.

2.5 APQP Elements in MPDS

The alignment of APQP elements is done using the timing plan of the Mahindra Product Development System (MPDS).

2.6 APQP Process Flow

Figure 2 shows the generic APQP Process Flow

Figure 1

APQP TIMING PLAN

MPDS Gateways

SI : Strategic Intent

SC : Strategic Confirmation

PA : Programme Approval

VV: Virtual Validation

PC : Programme Confirmation

PR : Product Readiness

PP : Production Prove-out

SO : Sign Off

LR : Launch Readiness

J1 : Job 1

FS : Final Status

SI

J 1

FS

PC

PR

PP

SO

LR

SC

PA

VV

Figure 2 : Generic Process Flow – APQP

End

GREEN

YELLOW/RED

Risk Assessment Y/R

APQP

Assessment

Green

APQP Status G/Y/R

Major Review Meeting including APQP Assessment Results

Start APQP Reporting

Initiate APQP Process

Management

establishes cross-functional team

Criteria for APQP

Start

3.0 The APQP Status Report

3.1 Purpose

The APQP Status Report summarises the status for the 23 APQP elements. The status report facilitates communication between Product Development, Manufacturing Engineering, Manufacturing Plants etc. It also provides a dated record that future programmes for reference.

3.2 Status Reporting Responsibility

For each of the 23 elements, there is a lead responsibility defined. This lead function obtains the necessary input/support from other affected functions and consolidates it into a G/Y/R (Green/Yellow/Red) status (per element) on the APQP status report form.(MQS/APQP/F01)

Reporting Requirements

The Project Team consolidates the APQP status report and present summary to senior management at all major Programme Reviews/ Gateways. Action plan is prepared for all Yellow & Red status.

Ratings and Assessment

4.1 G Y R Status

Green-Yellow-Red status communicates the progress toward the successful project completion of elements by the program need date. Program need date is the last possible date an element can be completed and not adversely affect quality, cost or timing of the program. The “GYR Status” column of the report shows the assessment for each element.Definitions/Risk factors for Red, Yellow, and Green are listed in the table below.

Risk

Colour

Definition

High

Red

Target dates and/or elements are at risk. A recovery Action Plan is not available and/or implemented, or the Action Plan does not achieve program targets. Late on time.

Moderate

Yellow

Target dates and/or elements are at risk, but a recovery Action Plan has been developed to achieve program targets, and has been approved by the appropriate Project Team. Target date can be met with management support.

Low

Green

Target dates and elements are on track and meeting objectives.

Each element shall be supported by relevant documented evidence like reports, circular, filled format, quality documents, scanned signoff copy etc. For this purpose MQS & PQO recommends the use of appropriate softwares like Excel, Word, Power point, MS Project, etc with hyperlinks to the document.

Any item once become red will remain red & Yellow/Green will be superimposed appropriately to show latest status.

4.2 The 8 Focus Elements :

For all 23 elements, quality expectations are defined in this Guideline. Out of the 23 elements, the following 8 elements are considered as Focus Elements :

Design FMEA

Design Verification Plan

Prototype Build Control Plan

Manufacturing Process Flow Chart

Process FMEA

Pre-Launch Control Plan

Operator Process Instructions

Production Control Plan

These elements when completed with Quality and On Time lay the foundation for Programme success.

The 8 Focus Elements are assessed for Quality of Event using Focus Element Rating Checklist.

4.3 Status Report Descriptions :

Build Level : Indicates the level of Build such as Engineering Prototype, Verification Prototype, Production Trial Run, Job # 1, etc.

PIST : Percentage of Inspection points that satisfy Specified Tolerance (all points).

PIPC : Percentage of Indices which are Process Capable (Percentage of Critical & Significant Characteristics with Pp & Ppk greater than or equal to 1.67 for the pre-production phase and Cp and Cpk greater than or equal to 1.33 for production phase).

SC & CC (Special Characteristics) : All products and processes have features described by characteristics which are important and need to be controlled. However, some characteristics called special characteristics require extra efforts to minimise the risk of potential adverse consequences.

Special Characteristics consist of –

1. Critical Characteristics are those product or process requirements that affect compliance with government regulation or safe vehicle/ product function AND which require special actions/ controls.

Product or process requirements can include dimension, specification, tests, processes, assembly sequences, tooling, joints, torques, welds, attatchments, component usage etc.

Symbol : <CC>

Severity Rating : 9 or 10 for any occurrence rating.

2. Significant Characteristics are those product, process, and/ or test requirements which are important for customer satisfaction AND for which Quality Planning actions must be summarised on a Control Plan.

Symbol : <SC>

Severity Rating : 5 to 8 Occurrence Rating : 5 and above

For further details please refer Charachteristics Classification Guideline,

MQS/CC&SC/GL01

The 23 APQP Elements

5.0 APQP Element Description Description DescriptionThe following pages include an in-depth view of the 23 APQP elements. Each element is split into six separate areas. These areas are :

Definition – identifies the motivation behind the element.

Expectations – defines the requirements for the element.

Lead Responsibility – identifies the function responsible for lead reporting . Identifies function that all others will support in completion of the element.

Support function – identifies the support functions that will provide input to the Lead Responsibility.

Timing – Identifies the initial and final Gateway timing for the element with respect to Total Project Work Plan (TPWP).

Deliverables – indicates the items that must be completed during time frames specified for the element.

.

11. Sourcing Decision

Definition

Sourcing Decision is a formal customer commitment to work on a timely basis with internal and external suppliers on the programme.

Expectations

The Sourcing Decision is completed and communicated to internal and external suppliers before the Programme Need Date.

The sourcing need dates for all components, systems and vehicles are established.

Lead Responsibility

Project Team/CFT for in-house sourced components / aggregates.

Material Management.(MM)

Support Functions

Supplier Upgradation

Product Development

Strategic Sourcing

Manufacturing Plant

Manufacturing Engineering

Timing

Initiate Milestone < PA >

Finalise Milestone < VV >

Deliverables

Establish a Timing Plan for completion of Sourcing Decisions.

Start communication with potential in-house manufacturers for “make parts” and with suppliers for “buy” parts.

Identify long -lead items (i.e. sourcing for new facilities, implementation of single sourcing strategies for Assembly Plants, etc.)

Evaluate the percent of completion for the Sourcing Decision Element at the beginning of each month between < PA> and <VV>.

Sourcing Decision for long-lead items is completed and communicated.

Open issues are identified and agreed upon by Project Team/CFT .

The Soucing Decision is completed and communicated.

22. Customers Input Requirement

Definition

The Customer Input Requirements Element is used to initiate the Quality Planning process through identification of design criteria and programme requirements.

Quality Function Deployment, (QFD) is one of the mechanisms to generate the Customer Input Requirements.

Expectations

Design goals (specified through customer survey) are translated into tentative and measurable design objectives.

The Project Team/CFT must receive initial system and component designs and specifications from R&D Centre including

– Product Assumptions

Functional Performance

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Weight

Material

Reliability and Quality goals are established based on

Prior model product and process concern history

Customer wants and expectations

Programme objectives

Reliability bench-marks

The reliability and quality goals must include the following:

Useful life Reliability Targets

Warranty Targets ( R/1000)

Incoming quality targets (parts per million, defect levels, scrap rates)

Functional Targets

Note: The above targets should be supplied as appropriate to the system, subsystem, or component.

The Programme Timing Plan is established to meet the customer needs and expectations by identifying the Timing Requirements for the following:

Tasks

Assignments

Events

Programme Timing Date must be communicated for the following:

Programme status reviews

APQP Plans

Design Freeze

2Prototype builds

In Plant Dates

Job #1

Affordable cost targets have been communicated for the vehicle, system, sub-system and components.

Capacity Planning volumes have been provided to the supplier (external and internal)

A list for Key Contact Personnel within M&M – the Project Owner, Project Manager, Design Leader, Manufacturing Engineering Leader, Launch Leader, MM Leader, Supplier Upgradation Leader and others as appropriate – is established. The list should include name, location, e-mail address and phone number.

Lead responsibility

Product Development

Support Functions

Manufacturing Engineering

Manufacturing Plants

MM

Marketing

Project Team/CFT

Assembly Plant assigns a Launch Manager to support all necessary activities at the <PA>Milestone and beyond. The Assembly Plant prepares a want list of preferable product and process improvements. The Wants List is prepared based on customer data and manufacturing process capabilities of current running production models. When necessary, quality, cost, and timing data shall be presented to lead activities.

Timing

Initiate Milestone <KO>

Finalise Milestone <SC>

Deliverables

Establish Plans to develop:

Design goals

Reliability and Quality goals

Programme Timing

Cost Targets

Capacity Planning Volume

– Key Contact Personnel

2The Programme Steering Team recognizes and supports the criteria identified in the expectations.

A manufacturing strategy is identified and available.

The preliminary Product and Business Targets are defined in sufficient detail to initiate Engineering projects at the <PA> Milestone.

The Programme Core Team is identified.

Resources are identified and committed by all affected functions.

The Total Programme Work Plan (TPWP) is developed and agreed upon by the Programme Core Team including APQP deliverables.

The manufacturing requirements (must/ wants) are available, consolidated and submitted to the Programme Core Team.

Objectives, Targets and Plans for the above desired expectations are completed, confirmed and communicated to all sources and planning activities.

The TPWP (including APQP deliverables) is signed off.

33. Design FMEA

Definition

A Design or Concept FMEA is a systematic approach (used by the design responsible team) which assures that potential design failure modes and associated causes are considered and addressed.

Expectations

DFMEAs are led by Product Engineering, prepared with a cross-functional team, and follow the guidelines laid down in the MQS FMEA Manual.

DFMEAs prepare for new product features, technologies, and product development quality concerns unresolved during the previous model lifetime.

DFMEAs are essential in developing Prototype Build Control Plans and the Manufacturing P/ FMEAs.

Unanticipated failure modes encountered during design verification testing must be addressed in the D/ FMEA.

Potential Special Characteristics <CC> & <SC> are identified.

Lead Responsibility

Product Development

Support Functions

Manufacturing Engineering

Manufacturing Plants

Customer Care

Timing

Initiate Milestone <VV>

Finalize Milestone <LR>

Deliverables

Initial

Establish a list of Concepts, Systems, Sub-systems etc on which DFMEA needs to be conducted and write out a DFMEA Timing Plan.

Intermediate

Review percentage of DFMEA completion at all Milestones between <VV> and <LR>

Final

100% of the DFMEAs are complete and all necessary actions to minimise quality risks are implemented.

Potential <CC> & <SC> are identified.

4 Design Reviews

Definitions

Design Reviews are regularly scheduled meetings led by the design responsible activity and must include any affected areas, such as, Manufacturing Engineering, Plant personnel etc. The review process includes the following:

A series of verification activities that are more than engineering inspection.

An effective method to prevent problems and misunderstandings.

Provide a mechanism to monitor progress and report to the management (including the review of APQP open issues)

Expectations

The Design Feasibility concerns are resolved in time to support each build In-Plant Date.

Review the progress of the Design Verification Plan and Report (DVP&R)). Unanticipated failure modes encountered during design verification testing must be addressed in the DFMEA.

Review any open APQP issues.

Review the progress toward achieving reliability, quality, cost and timing targets.

Lead Responsibility

Product Development

Support Functions

Manufacturing Engineering

Manufacturing Plants

Customer Care

MM

Timing

Initiate Milestone <SC>

Finalize Milestone <LR>

Deliverables

Develop a Design Review Plan.

Define roles and responsibilities

Develop a Design Review work plan one month prior to the initial Design Review

4

Evaluate the progress of DVP&Rs

Review the significant and critical characteristics identified in the Engineering Specifications.

Concerns are identified at each Milestone from <SC> to <LR>

100% of the open design issues are resolved

The Project Team/CFT present the lessons learned from the Programme.

For further details please refer Design Review Guideline,

MQS/DR/GL01

5Design Verification Plan &Report

Definition

The Design Verification Plan & Report (DVP&R) is a document listing the engineering evaluations, tests, and reports required to establish a design fit for use in the intended environment and meets the customer driven objectives and the intent with which the product / process was designed. The design verification plan has a correlation with the Customer Input Requirement.

Expectations

The DVP&R is a team approach

Identification of specific tests, methods, equipment, acceptance criteria, sample sizes, design level and timing must be contained in the DVP&R.

Tests must include variation within tolerance on team selected product characteristics.

The Design Verification must include:

Test requirements for design, material, or manufacturing process that apply to the production trial.

Tests, which address for the customer usage profile and duty cycle.

Tests which address the useful life of the product.

Tests which address the effects of the external environment (climate, road surface conditions etc)

Tests which address the effects of physical interfaces between components or systems.

Lead Responsibility

Product & Reliability Engineering

Support Functions

Manufacturing Engineering

Manufacturing Plants

Customer Care

Support Functions have skilled personnel assigned to review and confirm the DVP&R results and specification settings for significant and critical characteristics.

Applicability

Design Verification Plans and Reports are used for the following schedules,

Development Prototypes.

Product Validation.

Product Life Cycle.

5Design Verification Plans and Reports include the following tests

Engineering Development Tests: Performed during product design for functional development, for detecting time dependent failures.

Design Verification Tests : Performed to demonstrate that the design samples meeting production intent environmental, functional, reliability and durability requirements

Production Validation Tests: Performed to demonstrate that the design samples from the production environment meet all requirements similar to Design Verification tests and assure that no adverse variables have been introduced.

Continuous Conformance Tests: Performed on an on going basis to assure contained compliance to all Product &Process requirements.

Timings

Initial Gateway <VV>

Finalize Gateway <LR>

Deliverables

Develop the DVP&R and appropriate review process

The DVP&R is complete and the identified metrics enable comparison with target metrics at Engineering Prototype review.

DVP&R is updated and a draft of the Engineering specification is available as per MPDS Guideline.

The DVP&R is complete in order to support the Verification Prototype (VP) builds.

All Engineering specifications, up to and including job #1 design level are confirmed and released.

All verification and validation tests are completed.

6Subcontractor APQP Status (Tier 1 Supplier)

Definition

The Subcontractor APQP Status identifies and reports on the condition of an external Supplier or Subcontractor’s APQP process. It is required of Supplier to cascade APQP requirements to their suppliers or subcontractors and conduct APQP reviews as appropriate. The results of these reviews are summarised on the APQP Status Report.

Expectations

All suppliers must assess risk and specify the level of their suppliers APQP participation.

Subcontractors that affect significant and critical characteristics must follow all APQP disciplines.

Suppliers will allocate sufficient resources to work with their subcontractors as part of the cross-functional APQP effort.

Suppliers will hold regularly scheduled APQP status reviews with their subcontractors.

Concerns are reported to the customer and action plans are developed for elements that do not meet quality, cost and timing objectives.

Lead Responsibility

MM

Support Function

Supplier Upgradation.

Timing

Initiate Gateway <VV>

Finalize Gateway <LR>

Deliverables

Communicate to all relevant suppliers the expected APQP deliverables in line with Programme Need Dates (In Plant Dates).

Provide a Subcontractor APQP status at each Milestone

100% of approved PSW parts delivered before <SO> Gateway

100% of the supplier’s open issues are resolved to support on-going production

7 Facilities, Tools & Gauges

Definition

The Facilities, Tools and Gauges element identifies the new, additional, refurbished and relocated resources necessary to manufacture the customer specified product at designated quantity and quality levels.

Expectations

Facilities, planning approval, drawings and utilities must be included on the Product Timing Plan and funding approval must be complete.

Machinery FMEA needs to be completed before releasing the Design Approved Print (DAP)

SPC & MSA and acceptance criteria must be team approved before sourcing of Facilities, Tools or Gauges can be approved.

Trial runs should occur at the machine builder’s location to qualify all Facilities, Tools and Gauges.

All corrective actions for Facilities, Tools and Gauges not meeting customer requirements must be completed prior to the Production Trial Run.

Facilities, Tools and Gauges must be delivered, installed and approved prior to the Production Trial Run.

Lead Responsibility

Manufacturing Engineering

Support Functions

Manufacturing Plants

Project Engineering

Asset Management

Timing

Initiate Gateway <VV>

Finalise Gateway <LR>

Deliverables

Establish a Manufacturing Strategy.

New Technologies are identified.

Hard points for manufacturing process facilities and complexity are established.

Long lead funding is identified for major Facilities, Tools and Gauges at the <VV> Milestone.

7

Tooling for the VP0 build is confirmed and available before <PC> Gateway clearance

Readiness for PP(Production Proveout) assembly is confirmed at before <PP> Gateway clearance

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Facilities, Tools and Gauges are installed &listed in the Process Sheets.

Equipment safety is verified.

Concerns are resolved.

8Prototype Build Control Plan

Definition

Prototype Build Control Plan (PBCP) is a description of the control factors that will be used to manufacture and assemble a prototype build. In the control plan evaluation process, PBCP is the first summary document. This document is necessary to align the responsible activities process steps to both the significant / critical product characteristics and customer targets.

Expectations

A cross-functional team led by the Product Engineering develops the Prototype Build Control Plan.

The Prototype Build Control Plan is to be reviewed at each Design Review and is an essential part of the Team Feasibility Commitment.

All relevant records of Part Quality Inspection before Build are mandatory.

Lead Responsibility

Product Development

Support Functions

Manufacturing Engineering

Manufacturing Plants

Timing

Initiate Gateway <VV>

Finalize Gateway <PR>

Deliverables

Establish a work plan for Prototype Build Control Plan development.

Review the percentage of Prototype Build Control Plan completion at each design review.

The Preliminary Prototype Build Control Plan is available at <PC> Gateway

A draft of the engineering specifications needed for the PBCB is made available at Gateway <PC>.

All relevant drawing and engineering specification results, upto and including Job 1, is summarized in the Prototype Build Control Plan.

All significant/critical characteristics are reviewed during the prototype build phase.

Lessons learned are identified.

Feasibility commitment of final Prototype Build Control Plan characteristics is available.

9Prototype Builds

Definition

The Prototype Builds Element entails the manufacture or assembly of components, systems or sub-systems, and assembled vehicles that will be supplied to the customer for builds occurring prior to the Verification Prototype (VP) Build phase.

Expectations

All customer prototype material will meet the following requirements by the

In Plant Date.

Correct level parts

Customer specification data.

Customer approval for all non conformances.

The Prototype Build Control Plan was followed in the manufacture or assembly of the Prototype Builds.

Lead Responsibility

Product Development

Support Functions

Manufacturing Engineering

Manufacturing Plant

MM

Timing

Initiate Gateway <PC>

Finalize Gateway <PP>

Deliverables

Timing Plan for Prototype Builds is established.

100% of the parts are available before the <PR> Milestone.

All planned Prototype Builds are in line with the Timing Plan.

Quality level is verified based on the requirements established in the Prototype Build Control Plan.

Concerns are identified and documented.

9Timing Plan for VP Prototype Builds is established.

PSW status is fully identified for all parts necessary for each prototype build.

All planned Prototype Builds are in line with the Timing Plan

Quality level is verified based on the requirements established in the Prototype Build Control Plan.

Concerns are identified and documented.

For complete Build definition and its application please refer MQS website under MPDS Section.

Please refer Supplier’s Master Schedule for build details (MQS/APQP/F 021)

1010. Drawing and Specifications

Definition

The Drawing and Specifications Element refers to all engineering drawings, CAD data, material specifications and engineering specifications.

Expectations

The Programme Need Dates must be communicated to the customer.

Note: the Drawing and Specifications Programme Need Date is the last possible date the supplier can accept a design change and support PSW (Part Submission Warrant) delivery at the Material Required Date.

PPRF/PR drawings are applicable for protobuilds.

Change cutoff for final drawing release should take place before

Pre-launch build.

Drawings and specifications must include

Engineering specification tests

Product Validation Test requirements

The Product Development / Manufacturing Engineering personnel who will be assessing drawings and specifications to meet Programme Affordable Cost and Quality requirements are identified.

The drawing information and engineering specifications will be used as a prerequisite to the Prototype Build Control Plan.

Lead Responsibility

Product Development

Support functions

Manufacturing Engineering

Manufacturing Plants

Timing

Initiate Gateway <VV>

Finalize Gateway <SO>

Deliverables

Initial

Establish a Timing Plan to support all activities and build phases with Drawings and Specifications.

Assess the percent of completed drawings and specifications at each Gateway between <VV> to <SO>.

The Preliminary BOM (Bill of Materials) is established at <PA> Gateway

CAE analysis is complete and all necessary drawings are available for the Engineering Prototype Review.

10All necessary drawings are up dated and a draft of the Engineering Specification is available.

The BOM (Bills of Materials) reflecting PDB content is loaded into Metaphase (Engineering Release System) at the <VV> Gateway

100% of the drawings and Engineering Specifications are updated up to and including Job1 design level, are made available at the <SO> Gateway

100% of the Drawings and Engineering Specifications are updated.

All service parts are released.

11 Teams Feasibility Commitment

Definition

The Team Feasibility Element determines whether the proposed design can be manufactured within the guidelines. A cross-functional design review team is charged with assessing design feasibility. Once workability is established, the Programme Management Team undertakes the responsibility of following the design review process and reassessing feasibility for any design or part change that may occur during part development.

Expectations

The design review team must be satisfied with the following conditions:

The design is fit for intended use

The design can be manufactured, assembled, tested, packaged and delivered in sufficient quality to the customer on schedule.

Major feasibility concerns must be resolved prior to the Production Trial Run.

The manufacturing or assembly plant must assess risk and determine which of their suppliers must complete a feasibility assessment. Subcontractors who affect significant/ critical characteristics must complete a feasibility assessment.

A Team Feasibility Commitment is given if all activities agree to be able to produce a product within specification of significant / critical characteristics outlined in the relevant control plan.

The team must establish a formal feasibility document

Lead responsibility

Product Development

Manufacturing Engineering

Support Functions

Manufacturing Plants

Project Engineering

MM

Timing

Initiate Gateway <VV>

Finalize Gateway <SO>

11Deliverables

The Team feasibility commitment is scheduled in accordance with the Design Review Timing Plan.

The team feasibility commitment is to be reviewed at each Design Review.

Review the Prototype Build Control Plan Characteristics.

All activities agree to be able to produce the product in line within the specification of significant / critical characteristics outlined in the relevant control plan.

All feasibility concerns are resolved and necessary product and process changes are scheduled to be completed prior to the 1 PP (First Production Proveout) build phase.

12Manufacturing Process Flow Charts

Definition

The Manufacturing Process Flow Chart is a graphic representation of the current or proposed sequence of manufacturing process flow.

Expectations

A Manufacturing Process Flow Chart is developed as input to PFMEAs by a cross-functional team led by Manufacturing Engineering.

Lead Responsibility

Manufacturing Engineering.

Support Functions

Manufacturing Plants.

Product Engineering

Timing

Initiate Gateway <VV>

Finalize Gateway <LR>

Deliverables

Develop a plan to establish process flow charts for new processes / technologies, in line with the PFMEA schedule.

Process sheets initiated at<VV>.

Manufacturing Process Flow Charts are available to initiate PFMEAs

100% of Manufacturing Process Flow Charts are available.

Final Process Sheet available before <LR>.

For further details, please refer Guideline on Dynamic Control Planning,

MQS/DCP/GL01.

1313. Process FMEA

Definition

A Process FMEA is a systematic approach used by a manufacturing responsible team to assure that potential process related failure modes and their associated causes have been considered and addressed.

Expectations

All PFMEAs are prepared by a cross-functional team led by Manufacturing Engineering following the MQS FMEA manual.

Quality risks identified from DFMEAs, which can not be resolved through Product design changes, require the initiation of a PFMEA.

PFMEAs must be established for all major quality concerns not resolved during the current production model year, all new processes/ technologies, and new product features.

A finalised DFMEA is not a mandatory prerequisite to perform a PFMEA.

Lead Responsibility

Manufacturing Engineering

Support Functions

Product Development

Manufacturing Plants

Customer Care

Timing

Initiate Gateway <VV>

Finalize Gateway <LR>

Deliverables

Establish a PFMEA plan in line with the above described expectations.

Initial PFMEAs are established for new or critical systems.

100% PFMEAs are performed in line with the development plan and necessary actions are identified and planned before <PC> gateway clearance.

100% PFMEAs are performed and all identified actions are implemented before <LR>.

A list of confirmed <CC> & <SC> is available.

For further details, please refer MQS Guideline on Potential Failure Mode & Effects Analysis, MQS/FMEA.

14Measurement System Evaluation

Definition

Measurement Systems Evaluation assesses the variation of the measurement system and determines whether the measurement system is acceptable for monitoring the process.

Expectations

The appropriate Measurement Systems Evaluation methods, standard acceptance levels, and statistical and analytical requirements will be performed following the MQS/MSA/GL01Guideline.

All measurement systems (gauges and test equipment) must be modified to reflect the latest engineering part level prior to the Production Trial Run.

The Measurement systems development plan must follow the evolution of the Control Plans (Prototype, Pre-launch and Production)

The user must be given the opportunity to review and concur with the gauges and test equipment study results prior to the Production Trial Run.

The Measurement System Evaluation for <SC> <CC> is mandatory and must be repeated and approved following all gauge and test equipment modifications.

Lead Responsibility

Manufacturing Engineering

Support Function

Manufacturing Plant

Product Development

Timing

Initiate Milestone <VV>

Finalize Milestone <LR>

Deliverables

Establish measurement systems development plan in line with Prototype Build Control Plan characteristics.

Develop a Timing Plan for measurement equipment modifications and implementation of new systems.

The Measurement Systems Evaluation is in line with the programme build schedule

100% Measurement Systems are evaluated for carry over parts and necessary modifications are identified 100% Measurement Systems are identified.

14100% Measurement Systems Evaluation is performed and necessary modifications are identified.

100% measurement capability approval of all measurement system covering all significant / critical characteristics as outlined in the Production Control Plan.

For further details, please refer Guideline on Measurement System and Equipment Capability, MQS/MSA/GL01.

1515. Pre-Launch Control Plan

Definition

The Pre-Launch Control Plan is a written description of the dimensional measurements and material and functional tests that will occur after prototype build and before full production.

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Expectations

Development of the Pre-Launch Control Plan is led by Manufacturing Engineering, prepared with a cross-functional team and will follow the outline provided in the MQS APQP and Control Plan Manual.

The Pre-Launch Control Plan is initiated during the prototype build phase.

Results from the Prototype Build Control Plan and DFMEA provide an outline for the Pre-Launch Control Plan.

Lead responsibility

Manufacturing Engineering

Support Functions

Manufacturing Plants

Product Development

Timing

Initiate Gateway <PR>

Finalise Gateway <PP>

Deliverables

Develop a Timing Plan to establish Pre-Launch Control Plans.

Assess the completion status of the Pre-Launch Control Plan against the Programme Need Date.

The Pre-Launch Control Plan is 100% complete to support the 1PP build phase.

For further details, please refer Guideline on Dynamic Control Planning,

MQS/DCP/GL01.

1616 Operator Process Instructions (SOP or SOS)

Definition

Operator Process Instructions describe the details of controls and actions that operating personnel must perform to produce quality products.

Expectations

Operator Process Instructions are developed by a cross-functional team led by Manufacturing Plant

Operator Process Instructions describe all process steps necessary to produce a quality product, and include all essential visual aids and/ or detailed instructions to support the production operators.

Lead Responsibility

Manufacturing Plants

Support Functions

Manufacturing Engineering

Timing

Initiate Milestone <PR>

Finalise Milestone <LR>

Deliverables

Develop a Timing Plan for release of Process Instructions.

Plants begin reviewing Manufacturing Engineering processes to identify necessary visual aids for production.

The Assembly Process is available for specific, critical or new systems

Assess the progress of Operator Process Instructions in line with the Timing Plan to ensure availability of a Preliminary Process at the PP build phase.

The period between <PR> and <LR> will be used to verify and finalise the Operator Process Instructions

Plants have all visual aids identified.

Operator Process Instructions are 100% in place before <LR>

For further details, please refer Operator Process Instruction/SOP Guideline,

MQS/Operator Process Instruction/GL01.

1717. Packaging Specifications

Definition

The supplier of a product must ensure that individual packaging for shipment (including interior partitions) is designed and developed. Customer packaging standards should be used wherever available.

Expectations

Packaging requirements are agreed upon by the supplier and the receiving plant.

Packaging evaluation must test the packaging under the expected conditions of transport and material handling.

The packaging design must ensure that the product performance and characteristics will remain unchanged during packing, shipping and unpacking.

Feasibility of packaging is assured during Design Reviews.

Lead Responsibility

Manufacturing Engineering.

Support Functions

Product Engineering.

Manufacturing Plants.

Timing

Initiate Gateway <VV>

Finalise Gateway <SO>

Deliverables

Develop a Timing Plan for packaging development.

At each Milestone, packaging design is reviewed for appropriateness to the expected part quality level.

All necessary packaging trials are conducted during the PP Production Trial Run

All packaging specifications are available. All packaging facilities are in place at the suppliers and/or user plants.

For further details, please refer Packaging guideline for supply of production parts,

MQS/PKG/GL01.

1818. Production Trial Run

Definition

The production trial run is a validation of the effectiveness of the manufacturing and assembly processes using production tooling, equipment, environment (including production operators), facilities and cycle times. Output of the Production Trial Run is used for Production Part Approval and Manufacturing/Quality Planning Sign-Off.

Expectations

The Pre-launch Control Plan is followed during the Production Trial Run.

The Production Trial Run must be used to confirm or add linkages between product and process characteristics.

Preliminary Operator Process Instructions are followed during the Production Trial Run.

Corrective design and process actions must be established for concerns identified during the Production Trial Run.

Lead Responsibility

Manufacturing Plant (Launch Manager).

Support Functions

Manufacturing Engineering

Product Development

Timing

Initiate Gateway <PP>.

Finalize Gateway <LR>.

Deliverables

A Timing Plan for the Production Trial Run is established.

A Timing Plan for operator training is established.

100% PSW Status is identified for each build trial.

All product and process concerns are resolved before the start of the FEU(Field Evaluation Unit) build.

Completion of operator training is reviewed frequently between Milestones <PP> and <LR>.

Facilities, tools and gauges are implemented.

All product and process concerns are resolved.

Operator Process Instructions are finalised and in place.

The Production Control Plan is finalised and in place.

Production validation testing is completed.

Approved PSW parts are delivered. and Operator training is completed.

1919. Production Control Plan

Definition

The Production Control Plan is a written description of the systems for controlling parts and processes during full production.

Expectations

The Production Control Plan is developed by a cross-functional team led by Manufacturing Engineering, and is to follow the outline provided in the MQS APQP and Control Plan Manual.

The outcome of the prototype builds and the pre-launch control plan provides a basis for the Production Control Plan.

Lead Responsibility

Manufacturing Plant (Launch Manager).

Support Function

Manufacturing Engineering.

Timing

Initiate Milestone <SO>

Finalize Milestone <LR>

Deliverables

Develop a Timing Plan for the development of the Production Control Plan.

Preliminary Production Control Plan is 100% available prior to the FEU (Field Evaluation Unit) build phase.

Post – FEU, the Production Control Plan is ready and appropriately modified and in place.

The Production Control Plan is ready for on-going production.

All engineering specifications are reviewed.

All significant/critical product and process characteristics controlling the manufacture of parts and vehicle assembly (including paint) are included in the Production Control Plan.

For further details, please refer Guideline on Dynamic Control Planning,

MQS/DCP/GL01

2020. Preliminary Process Capability Study

Definition

The Preliminary Process Capability Study is a statistical assessment of the ability to produce product within specification.

Expectations

Preliminary Process Capability studies are to be performed following the MQS Guideline.

The statistical and analytical techniques used to determine capability must be acceptable to the customer.

Preliminary Process Capability studies must be performed as documented in the Pre-Launch Control Plan.

Preliminary Process Capability studies must be completed and the customer given the opportunity to review, before Production Part Approval.

Lead Responsibility

Manufacturing Engineering

Support Functions

Manufacturing Plants

Timing

Initiate Milestone <PR>

Finalize Milestone <LR>

Deliverables

Begin the process capability assessment for similar processes.

Develop a Timing Plan to perform statistical studies

100% necessary statistical studies are identified and the Timing Plan is confirmed

80% capability assessment is performed

100% capability assessment is performed

Concerns are identified and necessary changes for the product and processes are concerned.

The Timing Plan for verification at the PP build phase is established.

For further details, please refer

Guideline on Continuing Process Control & Process Capability Improvement, MQS/SPC/GL01.

Guideline for Process Potential Studies (Ppk) for Machine & Process Evaluation, MQS/Ppk/GL01.

2121. Production Validation Testing

Definition

Production Validation Testing refers to engineering tests that validate that products made from production tools and processes meet engineering standards.

Expectations

Parts for Production Validation Testing must be selected from the Production Trial Run, as per the sample sizes and frequencies outlined in the Pre-Launch Control Plan.

All customer – specified dimensional, material, functional and reliability tests must be completed prior to Production Part Approval. If not, appropriate action plans and customer approvals are required.

Lead Responsibility

Product Development / CQA

Support Function

Manufacturing Plant.

Manufacturing Engineering.

Timing

Initiate Milestone <PP>

Finalize Milestone <SO>

Deliverables

Develop a Timing Plan to produce parts, components, systems, sub-systems and vehicles for validation testing in line with Engineering Specifications outlined in the Pre-Launch Control Plan.

All produced parts, components, systems, and sub-systems are tested prior to the FEU(Field Evaluation Unit) build phase

All required Engineering Specifications are tested and approval for acceptance is available.

For further details, please refer Production Validation testing (Engine) Guideline,

MQS/PV/GL01

2222. Production Part Approval

Definition

Production Part Approval is the documented verification that all customer engineering design requirements are met by the internal or external supplier, and the process has the potential to produce to these requirements, where applicable during an actual production run.

Expectations

All items of the MQS “Mahindra Production Part Approval Process” Manual must be completed and the required documentation provided to the customer with the Part Submission Warrant.

Production Part Approval is complete before the Material Required Date (MRD) for the User Plant’s Production Trial Run

Lead Responsibility

Manufacturing Plant / CQA

Support Functions

Manufacturing Engineering

Timing

Initiate Milestone <PP>

Finalize Milestone <SO>

Deliverables

A Timing Plan for the Production Part Approval Process is established.

100% PSW approval process is initiated and the total Programme PSW(Part Submission Warrant) status is evaluated.

100% PSW is approved.

2323. PSW Part Delivery at Material Required Date (MRD)

Definition

PSW part delivery at the Material Required Date (MRD) is the final date that fully approved (PSW) material must be received at the customer’s plant to support their Production Trial Runs.

Expectations

The customer’s Material Required Date must be included in the supplier’s Timing Plan.

Production Part Approval requirements must be completed prior to the MRD of the user plant.

Lead Responsibility

Product Development

Manufacturing Engineering

MM

Manufacturing Plant

Timing

Initiate Milestone <PP>

Finalize Milestone <SO>

Deliverables

Develop the material In Plant timing for builds between mile stones <PP> to <SO>

Establish a MRD review process

Assess PSW part delivery rate at each build.

100% approved PSW parts are available.

Abbreviations

Ad. NOVA – C

Advanced New Overall Vehicle Audit – Customer

CAE

Computer Aided Engineering

CED

Cause & Effect Diagram

DCP

Dynamic Control Planning

DFMEA

Design Failure Mode & Analysis

DOE

Design of Experiments

DAP

Design Approved Print

NOVA – B

New Overall Vehicle Audit – Body

NOVA – P

New Overall Vehicle Audit – Paint

PDI

Pre Delivery Inspection

PDT

Plant Driveline Team

PET

Plant Engine Team

PFC

Process Flow Chart

POS

Process operation sheet

PVT

Plant Vehicle Teams

QCRT

Quick response Concern Resolution Team

SOS

Standard Operating Sheet

SOP

Standard Operating Procedure

SQA

Supplier Quality Assurance

WSS

Work station standardization

BWT

Basic Working Team

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