Apqp B5095904

Sundweep_ APQP_Guard Assy LH/RH
Supplier Name: Part Number:
SUNDWEEP ENGINEERS PVT LTD. B5095904
Supplier Location: Part Name:
FARIDABAD
Supplier Code: Revision Level: Report Date:
7 D 24-Jun-2013
S/A F T MTG BRKT Escort Research Centre
Component Priority Level: HIGH
Lead Customer/Program:
Date: 16 Jan 2008 Revision: D Doc No: D_020_4_03 Page 1 of 34
Cover
Process Owner / Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Supplier APQP: Five Phases
GSQM
MANAGEMENT MESSAGE SUPPLIER REQUIREMENTS & SELECTION
APQP
PHASE 3 Product/Process Realization PHASE 4 Pre-PPAP
OTHER SUPPLIER REQUIREMENTS
PHASE 1 Supplier Kickoff & Planning
PHASE 2 Equipment & Tool Design
PHASE 5 Product/Process Validation & Launch
Identify TRW & Supplier team contacts/roles/responsibilities Communicate & initiate Key Supplier Metrics Initial supplier program plan and timing Conduct cross-functional component design review APQP requirements Equipment, tooling & gage design review Create APQP Progress Report Initiate Open Issues document Review Preliminary Capacity Study Review Manufacturing Feasibility
Preliminary Process Flow, PFMEA & Control Plan review Review Supplier DFMEA (when applicable) Create PCM; Identify subsupplier value chain Supplier master schedule review Review Key Supplier Metrics Update previous phase open issues/key documents
Supplier Packaging Requirements Analysis of process failures and effects Process Flow Chart Use PCM for Pre-Launch Control Plan Process Instructions Finalize process capability study plan Validation review of off-tool condition Floor plan layout Pre-qualify equipment / tooling / gauging at supplier Review Key Supplier Metrics Update previous phase open issues/key documents
Pre-Production Run
Finalize complete PPAP submission package Cross-functional Key Metrics review; OK to launch sign-off Launch Readiness Audit Confirmation of full volume Run at Rate Initiate Safe Launch Practice Final component packaging review Review Key Supplier Metrics Close out previous phase open issues/key documents
Process Capability Study Finalize PCM; Prepare for Safe Launch Finalize PFMEA and Control Plan Launch Readiness Audit; document in Key Metrics Supplier Ramp Plan Re-qualify equipment / tooling/ gauging at supplier Appearance Approval (when applicable) Supplier participates in Plant Readiness Review Review Key Supplier Metrics Update previous phase open issues/key documents
Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 2 of 34
5 Phases
SUPPLIER SENIOR MANAGEMENT SUPPORT
Process Owner/Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Supplier APQP: Table of Contents

Cover Table of Contents Introduction Shows the 5 APQP Phases and the activities that occur within them. Lists all of the forms and examples included in this workbook. Displays a pictorial representation of APQP elements tracked in the Progress Report in relationship to TRW's launch profile. Suppliers are required to create a Master Time Line for the launch of the awarded component(s). It is expected that a Gantt chart is used as the format. For those suppliers who do not have software available to meet this requirement, a blank time line is provided for their use.
Blank Time Line
Key Metrics Report
Key Metrics contain those elements that contribute to a successful launch. This form allows for five reviews. The minimum requirement is to use it at APQP-5. The APQP-5 report is generated at the time product is manufactured for the PPAP submission. The additional columns would either be used at the discretion of the SDE or based on circumstances that require additional reviews.
Key Metrics Graph
Visually displays and compares the results of the Key Metrics reports generated during APQP-4 and/or APQP-5. Operational definitions for the twelve key metrics. Explains the metric and its method of calculation.
Key Metrics Definitions
Progress Report Other APQP Tools
Reporting form for suppliers to track progress on all APQP deliverables. Embedded copies of the Component Design Review, Product Characterisitics Matrix, and Launch Readiness Audit. Form for showing multi-tier suppy chain relationships involved in providing the component/assembly to TRW. The information documented here will also be used in the creation of the Product Characteristics Matrix. An example of how a Supply Chain Map may appear for a typical metal component.
Supply Chain Map
Supply Chain Map Example Product Characteristics Matrix Tier II
The PCM is used initially to define and determine appropriate controls for special characteristics, other process critical features and customer touch points. This tab is used to define the process at TRW's direct supplier. Throughout the APQP phase of launch this form is used as the Pre-Launch Control Plan and also forms the basis for Safe Launch Planning. The use of this tab is identical to the functionality define above, with the exception that this is used to document the remaining supply chain's, below the Tier II supplier, impact on the critical features.
Product Characteristics Matrix Sub-Supplier
In Cell Check (Blank)
This form is used document inspection results for those characteristics and features identified on the Product Characteristics Matrix during the Safe Launch Plan implementation period.
Table of Contents
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Spariosu / Global Director, SDE
Supplier APQP: Table of Contents

In Cell Check (Example) SLP - Weekly QOS Report Open Issues An example of the In Cell Check.
Format to be used for a weekly summary of the inspection results from the Safe Launch Plan.
The action plan format used to document open issues, their actions and resolution throughout the APQP process. This combines several different action plans generated by different, individual tools into a single document. Lists the individuals involved in the component(s) launch, for both TRW and the supplier, and their respective contact information. This tab is optional and may be used as needed.
Contacts
Table of Contents
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Spariosu / Global Director, SDE
Supplier APQP: Time Line_S/A OF FUEL TANK MTG BKT

APQP PHASE Jul-13
29 30 31 10 11 12 13 14
Aug-13
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 10 11 12 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Sep-13
13 14 15 16 17 18 19 20 21
OUTPUT 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 3.1 3.2 J BRACKET Design FMEA Preliminary Capacity Study reviewed Manufacturing Feasibility reviewed Component Design Review Key Supplier Metrics initiated Supplier Project timing plan Open Issues Action Plan created TPH,PIPS& TQH Product Characteristic Matrix initiated Process flow chart PFMEA Control Plan Key Supplier Metrics reviewed Measurement/ Testing equipment
1. Supplier Kick-Off
X X X X X X X X X X X X X X X X X X X
O O O O O O O O O O O O O O O O O O O O O O
2. Equipment & Tool Design
Tooling
NOTCHING TOOL-1 NOTCHING TOOL-2 R246 BENDING TOOL NOTCHING TOOL-1 R292 BENDING TOOL NOTCHING TOOL-1 NOTCHING TOOL-1 PUNCHING TOOL BLANKING TOOL
COMPOUND TOOL
SUPPORT CHANNEL 3. Product/Production Realization TOP PLATE
SUPPORT ANGLE FUEL TANK GUSSET FUEL TANK MTG BKT WASHER ASSEMBLY
X X X X X
O O O
PUNCHING TOOL RECEIVING GUAGE
5. Product/ Process Validation &
3.3 3.4 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5.1 5.2 5.3
Capital equipment Training Process instructions Packaging Key Supplier Metrics reviewed ELV/IMDS Safe Launch Plan finalized Supplier Ramp Plan Plant Readiness Review Launch Readiness Audit Appearance Approval Process (when applicable) Key Supplier Metrics reviewed PPAP Launch Readiness Audit Run at Rate
4. Pre-PPAP
Page 5 of 34
5. Product/ Process Validation &
5.4 5.5 6.1 6.2 6.3 6.4 6.5 6.6 6.7
Key Supplier Metrics reviewed OK to Launch Sign-Off
6. Other Requirements
KEY:
X Planned start
MATERIAL INDENT. PRE MACHINING VMC/WIRECUT/MILLING ASSEMBLY TOOL TRAIL
Planned completion
Actual start
>
Actual end
Page 6 of 34
Page 7 of 34
Page 8 of 34
Page 9 of 34
Page 10 of 34
Sep-13
22 23 24 25 26 27
Page 11 of 34
Page 12 of 34
Supplier APQP: Key Metrics Elements Graph

Supplier Name: Part Number: SUNDWEEP ENGINEERS PVT LTD. B5095904 HIGH Supplier Location: Part Name: Lead Customer/Program: FARIDABAD Supplier Code: Revision Level: Report Date: 7 D 24-Jun-2013
Component Priority Level:
CLICK ON THE BUTTON TO UPDATE THE "KEY METRICS STATUS" GRAPH:
Key Metrics Status
Primary Indicators
100%
100%
80%
80%
60%
60% 12 40%
APQP Readiness APQP Readiness
12
12
12
12
40%
APQP Readiness APQP Readiness APQP Readiness
GSQM 220
GSQM 220
GSQM 220
20%
0-Jan-00
0-Jan-00
0-Jan-00
0-Jan-00
0%
Key Metric Values at Review
APQP Readiness
100.0%
GSQM 220 Instructions
80.0% 60.0%
Ramp Plan FTC
40.0% 20.0%
PPAP Completion
0.0%
Process Efficiency
Sub-Tier PPAP
Capability
LRA % Process Complete

0-Jan-00 0-Jan-00 0-Jan-00
Testing
0-Jan-00
0-Jan-00
APQP Element Graphs
0-Jan-00
0%
GSQM 220
GSQM 220
Capability
Capability
Capability
Capability
Capability
20%
LRA
LRA
LRA
LRA
LRA
Supplier APQP: Key Supplier Metrics Report

Supplier Name: Part Number: SUNDWEEP ENGINEERS PVT LTD. B5095904 HIGH Supplier Location: Part Name: Lead Customer/Program: FARIDABAD Supplier Code: Revision Level: Report Date: 7 D 24-Jun-2013
Primary Indicator: Goal Production Preparation Influencing Factors Number of 'Progress Report' elements with Green status 1. APQP Readiness Total number of elements from'Progress Report' Total number of instructions completed MANUFACTURABILITY 2. Process Instructions Total number of instructions needed. Results from Run at Rate, line 25 3. First Time Capability Ideal % of good parts Overall Utilization percentage. 4. Process Efficiency Maximum allowable utilization Number of capable designated characteristics features 5. Process Capability Total number of designated characteristics features 6. Test Achievement 7. Process Implementation % Completed 8. Launch Readiness Audit 9. Sub-Component PPAP Approvals 10. PPAP Package Completion 11. Supplier Ramp Plan DLN Number of tests passed % of total tests High volulme process or Interim Process with Concession Production volumes provided off production intent process Score achieved during event Goal is 100%. Number of sub-components and materials PPAP approved Total number of purchased sub-components/materials Number of PPAP required documents completed Number of PPAP required documents required State of completed supplier ramp plan Ramp planned completed and shipping to releases Enter completed stage of PCM (see comments) Complete Stage 5 by SOP 5 5 5 Target Results
K E Y M E A S U R E A B L E S
PPAP
12. GSQM 220 Deployment
SUPPLIER SIGN-OFF (MANAGER LEVEL) Function Name (print) Signature Project Leader Purch/Sales Production Control Quality Engineering Design Manufacturing
TRW SIGN-0FF SDE TRW Internal Use only Commodity Mgr/Buyer SQA Name (print) Name (print) Name (print) Signature Signature Signature
Key Metrics Report
APQP: Key Supplier Metrics Operational Definitions

This section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP appro
Metric APQP Readiness
Definition Data is derived from the 'APQP Progress Report'. This metric tracks the percentage of GREEN elements compared to the total number of elements being tracked.
Goal
Results Enter the number of GREEN elements at the time of the report.
Enter the total number of elements being tracked. There are 33 elements on the APQP Progress Report. For suppliers where the DFMEA does not apply subtract 1. For suppliers who are not providing an Appearance item, subtract 1.
Process Instructions
Total number of set-up, manufacturing and inspection instructions needed. Enter total number of process instructions needed for serial production.
Enter number of completed process instructions at the time of the review.
First time Capability
Percentage of good parts to the total number of parts produced during the Run at Rate.
Form No.: D_020_4_12
Enter, as a decimal number, the ratio of total parts produced to good parts from the trial run. Enter the number '1,' which represents the production of 100% good, or usable, parts. The Overall Utilization % from the Run at Rate form. Maximum allowable utilized capacity is 100% when the standard shift pattern and CPV are used.
Process Efficiency
This is the percentage that the process is utilized.
Process Capability
The number of designated characteristics with a Ppk > 1.67. Enter the total number of designated characteristics on the drawing.
Enter the number of characteristics, with a Ppk > 1.67, at the time of the review.
Test Achievement
Total number of performance and materials tests that need to be conducted to meet the specifications shown on the drawing. This number is a combination The should represent the total number of of the number of unique tests multiplied individual tests required times the number by the number of samples required for of samples, for each test, that is required. the test.
This is the total number of samples that passed all of the required testing at the time of the review.
Process Owner/Department: R. Sparisou / Supplier Development Approved by: R. Blanchette / Global Director, SDE

Metric
Definition
Goal
Results Enter the appropriate stage of process implementation in regard to manufacturing for serial production. 1. Prototype process is implemented; No released deviation of concession; No containment plan. 2. Intermim process implemented, with partial production intent process; No released deviation or concession; No containment plan. 3. Prototype or partially implemented process; Released deviation or concession; No containment plan. 4. Partial or fully implemented process; Released deviation or concession; Containment plan implemented. 5. Fully implemented process; No deviation or concession required
APQP Readiness is derived from the Progress Process Implementation - Data This metric assesses the'APQP level of Report'. This metric tracks the % Completed implementation of the full production percentage of GREEN elements intent process. Processes that are not compared to the total number of fully implemented at the Start-ofelements being tracked. Production require a deviation, or concession, to allow shipment. This document needs to clearly define the state of the process implementation, provide a time line for completing the implementation, list any non-conformities to the drawing and/or specifications, and a containment plan to keep those nonconformances from reaching TRW.
5. Fully implemented process; No deviation or concession required. Launch Readiness Audit A comprehesive audit tool's score, which assesses a process's state of preparation to meet serial production requirements. Form No.: D_020_4_09 The minimum goal for full release for production is 90%. Goal is 100% and entered as "1". The number of approved sub-component and material PPAPs at the time of the report. The score achieved on the Launch Readiness Audit. Enter data as a decimal number.
Sub-Component PPAP Approvals
Number PPAPs approved for the purchased sub-components and materials that makes up the final shipped component/material, and that do not have The number of approved sub-component any deviations, waivers, and/or and materials making up the shipped concessions granted by any tier below component/material. TRW. Number of PPAP submission package elements completed compared to required number. The total number of required elements, or documents, required to be submitted.
PPAP Package Completion
The number of elements (or documents) completed for the PPAP package at the time of the review.

Metric APQP Readiness Supplier Ramp Plan
Definition Data element is derived from thea 'APQP Progress This evaluates supplier's ability Report'. This metric tracks to meet ramp-up timing andthe volumes. percentage of GREEN elements compared to the total number of elements being tracked.
Goal
Results Enter the number corresponding to the completed stage from the list below. 1. Has not received any production releases from using plant(s). 2. Is receiving production releases from the using plant(s), but no production schedule or plan documented to meet those volumes or has ramp plan, is receiving plant releases, but is not shipping to plan and/or releases . 3. Has not received production releases from plant(s), but has created a preliminary planned based on quoted volumes and program timing. 4. Is receiving production releases and has created a plan, but production schedule does not reflect the plan. 5. Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule.
Enter the goal, Level 5-Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule. GSQM 220 Deployment This element provides status of the completion of the safe launch plan, on the PCM (D_020_4_20). Enter number of completed stage at time of review. Enter the number '5' representing the completion of the PCM, less the exit from the Safe Launch Plan. This applies to situations where the PPAP will be submitted in a span of time from before SOP to 30 days after SOP. Enter the number '6' for situations where the SLP exit is required for closing APQP.
Supplier APQP: Progress Report - Status Overview
Supplier Name: Part Number:
SUNDWEEP ENGINEERS PVT LTD. B5095904 HIGH
Supplier Location: Part Name: Lead Customer/Program:
FARIDABAD S/A F T MTG BRKT Escort Research Centre
Supplier Code: Revision Level: Report Date:
7 D 24-Jun-2013
PROGRAM MILESTONES Event Design Freeze First Off-Tool First Off-Process PV Build PPAP submission Start of Production Date Committed Event Date Committed
Needed
Completed
Needed
Completed
PHASE/ELEMENT STATUS OVERVIEW APQP Phase 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 2.2 2.3 2.4 2.5 2.6 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5.1 5.2 5.3 5.4 5.5 Date 20 Element Design FMEA Preliminary Capacity Study Manufacturing Feasibility reviewed Component Design Review Key Supplier Metrics initiated Supplier Project timing plan Open Issues Action Plan created Subcontractor PPAP approval Product Characteristic Matrix Process flow chart PFMEA Control Plan Key Supplier Metrics reviewed Measurement/ Testing equipment Tooling Capital equipment Training Process instructions Packaging Launch Readiness Audit Key Supplier Metrics reviewed ELV/IMDS Safe Launch Plan finalized Supplier Ramp Plan Plant Readiness Review Launch Readiness Audit Appearance Approval Process Key Supplier Metrics reviewed PPAP Launch Readiness Audit Run at Rate Key Supplier Metrics reviewed OK to Launch Sign-Off Needed Committed Complete Percent 100 40 60 80 Status
Issues / Recovery Plan / Actions
Progress Report
Supplier APQP: Other Tools
COMPONENT DESIGN REVIEW
NA
CLICK HERE
PRODUCT CHARACTERISTICS MATRIX
Applicable
CLICK HERE
LAUNCH READINESS AUDIT

Applicable
CLICK HERE
PPAP CHECKLIST
Applicable
CLICK HERE
Other APQP Tools
Supplier APQP: Supply Chain Map

Supplier:
Tier V
SUNDWEEP ENGINEERS PVT LTD. Part Number:

Tier IV Tier III
B5095904
Tier II
Date:
Customer receiving Operation
Revision:
OEM Customer Tier
Supply Chain Map - Form
Supplier APQP: Supply Chain Map - Example

TIER 4 SUPPLIER TIER 3 SUPPLIER TIER 2 SUPPLIER
Kojak Heat Treat Benton Harbor, MI Harden & Draw Fine Fasteners, Inc. Benton Harbor, MI M8x20 Weld Stud 59039813A Cold Forming
Anaconda Steel Erie, PA C1038 Rod Steel Mill
White & Jones Jackson, MI C1038 Rod Wire Draw, Anneal
3rd Party Warehouse TIER 1 SUPPLIER
CUSTOMER
AAA Heat Treat Frederick, MD Harden & Draw ABC Nut Co. Summit, NJ M8x15 Staking Nut 59039812C Cold Forming
Precision Forming Amarrillo, TX Airbag Reaction Can 49019804A Stamping body, end caps, brackets
Saf-Store Mesa, AZ Warehouse Services
TRW Mesa Mesa, AZ OEM Z910
Pacific Steel Los Angeles, CA C1024 Rod Steel Mill
B&C Processing Georgetown, PA C1024 Rod Wire Draw, Anneal
TRW Alfdorf Alfdorf, Germany OEM Z910
Dynamic Chemical Supplies Tulsa, OK Coating materials, solvents
Zephyr Coatings Austin, TX E-Coat
Supplier Chain Map - Example
Process Owner: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
Supplier APQP: Product Characteristic Matrix

Part Name: Part Number/ Revision: Project/ Program: Supplier Name: Location: TRW Using Plant(s): PCM Revision Date:
Product Design Inputs

# Product Characteristic Level/ Class DFMEA Severity PFMEA Severity PFMEA Occurance PFMEA Detection
Supplier Process Control Information

RPN Control Method(s) Gauge R&R Sample Size / Frequency
Safe Launch Plan (SLP)

Control Method Sample Size / Frequency
Date: 29 April 2008 Revision: B Doc No: D.020.4.20 Page 22 of 34
D_020_4_20-PCM
Process Owner/Department: R. Blanchette / Supplier Development Approved by: / VP Purchasing




Safe Launch Plan duration is for 90 days after start of production unless otherwise specified. SLP data must be sent to TRW (check one):
Other:
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
Daily
Weekly
Monthly
Each Shipment
Other
Safe Launch Plan must remain in effect until TRW approves SLP exit. All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced during PPAP.
PCM APPROVALS
Name Position/ Title Signature Date Comments
TRWA SDE TRWA Plant SQA Supplier Representative
D_020_4_20-PCM
Supplier APQP: Safe Launch Plan Data and Exit Approval


# Product Characteristic Level/ Class

Cpk from PPAP
Date:
Quantity Inspected Quantity Rejected Ppk
Date:
Quantity Inspected Quantity Rejected Ppk
Date:
Quantity Inspected Quantity Rejected
Date: 25 Apr 2008 Revision: B Doc No: D.020.4.20 Page 24 of 34
D_020_4_20-SLP
Safe Launch Plan duration is for 90 days after start of production unless otherwise specified.
Other:
Enter accumulated production data where specified in this form. Use of the SLP Weekly QOS Form will be directed by TRW as necessary. Submit data to the TRW Plant per the agreed frequency on the Product Characteristic Matrix unless instructed otherwise by TRW. SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect. To exit SLP: Sign and submit this form with all data. Acceptablilty of SLP exit request will be determined by TRW SQA.
SAFE LAUNCH PLAN EXIT APPROVALS
Supplier Representative TRWA Plant SQA
D_020_4_20-SLP
Ppk
D_020_4_20-SLP
D_020_4_20-SLP
Safe Launch Plan: QOS Report

Touch Point Incident & PPM Monitoring
1 1 1 1 1 1 1 PPM 1 1 0 0 0
0.3
Pareto Failures By Process

1
0.9
0.8
0.7
1 Incident
0.6 Incident
0.5
0.4
0
0.2
0 0
Incidents PPM
0.1
0 0
Total 0 0 #DIV/0!
Fault No. Failure Mode Total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Action
WEEK Incidents QTY PPM Timing #DIV/0! W14 #DIV/0! W15 #DIV/0! W16 #VALUE! W17 #VALUE! W18 #DIV/0! W19 #DIV/0! W20 #DIV/0! W21 #DIV/0! W22 #DIV/0! W23 #DIV/0! W24 #DIV/0! W25 #DIV/0! W26 #DIV/0! W27 #DIV/0! W28 #DIV/0! W29
Date: 01 Aug 2005 Revision: C Doc No: D_020_4_05 Page 28 of 34
D_020_4_20-SLP - QOS
Process Owner/Department: K. Gillis / Supplier Development Approved by: E. Carpenter / VP Purchasing




D_020_4_20-PCM Sub-Supplier




Safe Launch Plan duration is for 90 days after start of production unless otherwise specified. SLP data must be sent to TRW (check one):
Other:
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
Daily
Weekly
Monthly
Each Shipment
Other
Safe Launch Plan must remain in effect until TRW approves SLP exit. All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced during PPAP.
PCM APPROVALS
TRWA SDE TRWA Plant SQA Supplier Representative
D_020_4_20-PCM Sub-Supplier
100% IN CELL KEY FEATURES VERIFICATION AND CUSTOMER TOUCH POINTS FEATURES TO BE QUALIFIED
Part Description
Operator Name:___________ Work Cell:_________ Verification Method Pass Quantity Inspected:____________Date:______________
1 2 3 4 5 6 7 8 9 10 COMMENTS :
The Items Qualified Are To Be Marked With "YELLOW" Paint.
Part Number
Supervisor Signature :
Date :
In Cell Check
Fail
Safe Launch Plan: In Cell Check Example

Special Work Instruction
Customer /Project:
OPERATION
1 2 3
FEATURES TO BE QUALIFIED
Part Description
Brake Assy RH
Brake Assy LH
Operator Name:___________ Work Cell:_________
1 2 3 4 5 6
* * * * *
* * * * *
Lining identification code Mass weight and rivet presence Date code on shoe PKB rivet crimped washer Pkb lever hook Wheel cylinder screw torque
Visual Visual Visual Visual Gap Gauge Air Torque /mark

The Items Qualified Are To Be Marked With "YELLOW"
* *
Part Number
COMMENTS : 14544002 14544001
Supervisor Signature :
In Cell (Example)
Date :
Fail
Quantity Inspected:____________Date:______________
Verification Method
Pass
Supplier APQP: Open Issues - Corrective Action Plan

Supplier Name: TRW Part Numbe(s): Customer Name: Launch Activity Date Launch Activity Customer Platform: Date Launch Activity TRW Product: Date SUNDWEEP ENGINEERS PVT LTD. Component Manufacturing Location: FARIDABAD Supplier Code: Issued by: Status: Action plan review Date scheduled Date actual Action plan review Date scheduled Date actual 7
Item Number
Source of Issue
Source Ref Number
Concern / Problem / Open Issue Description
Dates Action Opened Due Closed Status Responsibility
Distribution:
Open Issues
Part Number
Customer Name APQP: Contacts- APQP TEAM

Contact Information Function Name Dept. Tel. Customer Name Purchasing Fax. Commodity Mgr E-mail Adress/ Location Name Dept. Tel. Customer Name Purchasing Product Fax. Line Mgr E-mail Adress/ Location Name Dept. Customer Name Tel. Supplier Fax. Development E-mail Engineering Adress/ Location Name Dept. Tel. Customer Name Fax. Engineering E-mail Adress/ Location Name Dept. Customer Name Tel. Receiving Plant Fax. Logisitic & E-mail Packaging Adress/ Location Name Dept. Tel. Customer Name Receiving Plant Fax. Quality E-mail Adress/ Location Name Dept. Tel. Project management Fax. E-mail Adress/ Location Function Name Dept. Tel. Fax. E-mail Adress/ Location Name Dept. Tel. Fax. E-mail Adress/ Location Name Dept. Tel. Fax. E-mail Adress/ Location Name Dept. Tel. Fax. E-mail Adress/ Location Name Dept. Tel. Fax. E-mail Adress/ Location Name Dept. Tel. Fax. E-mail Adress/ Location Name Dept. Tel. Fax. E-mail Adress/ Location
Report Date / Revision
Contact Information
Supplier
Contacts

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Apqp B5095904

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Sundweep_ APQP_Guard Assy LH/RH

Supplier Name: Part Number:

SUNDWEEP ENGINEERS PVT LTD. B5095904

Supplier Location: Part Name:

Supplier Code: Revision Level: Report Date:

S/A F T MTG BRKT Escort Research Centre

Component Priority Level: HIGH

Date: 16 Jan 2008 Revision: D Doc No: D_020_4_03 Page 1 of 34

Supplier APQP: Five Phases

OTHER SUPPLIER REQUIREMENTS

PHASE 1 Supplier Kickoff & Planning

PHASE 2 Equipment & Tool Design

PHASE 5 Product/Process Validation & Launch

Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 2 of 34

SUPPLIER SENIOR MANAGEMENT SUPPORT

Supplier APQP: Table of Contents

Blank Time Line

Key Metrics Report

Key Metrics Graph

Key Metrics Definitions

Progress Report Other APQP Tools

Supply Chain Map

Supply Chain Map Example Product Characteristics Matrix Tier II

Product Characteristics Matrix Sub-Supplier

In Cell Check (Blank)

Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 3 of 34

Supplier APQP: Table of Contents

Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 4 of 34

Supplier APQP: Time Line_S/A OF FUEL TANK MTG BKT

2. Equipment & Tool Design

SUPPORT CHANNEL 3. Product/Production Realization TOP PLATE

PUNCHING TOOL RECEIVING GUAGE

5. Product/ Process Validation &

5. Product/ Process Validation &

5.4 5.5 6.1 6.2 6.3 6.4 6.5 6.6 6.7

Key Supplier Metrics reviewed OK to Launch Sign-Off

Supplier APQP: Key Metrics Elements Graph

S/A F T MTG BRKT Escort Research Centre

Component Priority Level:

CLICK ON THE BUTTON TO UPDATE THE "KEY METRICS STATUS" GRAPH:

Key Metrics Status

Key Metric Values at Review

LRA % Process Complete

Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 13 of 34

APQP Element Graphs

Supplier APQP: Key Supplier Metrics Report

S/A F T MTG BRKT Escort Research Centre

Component Priority Level:

12. GSQM 220 Deployment

Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 14 of 34

Key Metrics Report

APQP: Key Supplier Metrics Operational Definitions

Metric APQP Readiness

Enter number of completed process instructions at the time of the review.

First time Capability

This is the percentage that the process is utilized.

Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 15 of 34

Key Metrics Definitions

APQP: Key Supplier Metrics Operational Definitions

Sub-Component PPAP Approvals

PPAP Package Completion

Date: 16 Jan 2008 Revision: D Doc No.: D_020_4_03 Page 16 of 34

Key Metrics Definitions