Supplier APQP Requirements Matrix Revision Date

MY/Program: Actual" status symbol O item meets target (Shift + letter o)

Supplier Name: key: D item does not meet target; plans exist; low risk (Shift + d)
Part Number(s) C item does not meet target with high risk (Shift + c)
Part Name: N/ Anot applicable
Supplier Champion: note: D & C these items to be included on gap analysis sheet with actions
phone/e-mail
Magna Donnelly Program Management Process (PMP) Stage
MSR 4.1- date xx/yy/zz MSR 4.2- date xx/yy/zz MSR 4.3 - date xx/yy/zz MSR 4.4 - date xx/yy/zz MSR 5 - date xx/yy/zz
APQP Elements Target Actual Target Actual Target Actual Target Actual Target Actual
Preliminary DFMEA created for supplier DFMEA reviewed and signed for DFMEA updated to current design level DFMEA updated to current design level
responsible components or supplier has supplier responsible components or
reviewed Magna Donnelly (MD) DFMEA. supplier has reviewed MD DFMEA.
High RPN’s have action plans with timing
High RPNs have action plans with
timing that meets tool kick-off date.
1. Design FMEA
Initial design review complete with 100% design concerns addressed. AIAG Design changes reviewed and 100% Design changes reviewed and 100% Design changes reviewed and 100%
supplier and MD per AIAG A-2 or A-2 checklist or equivalent complete and acceptable acceptable acceptable
2. Design Review) equivalent open issues resolved
Agreement with MD on performance and Prototype testing and measurement is All DV testing to specifications is initiated All DV testing complete. Test results
functional validation plan; Identify key 100% complete. per plan confirm product meets all requirements
dimensional characteristics for layout on
3. Design Verification Plan prototypes

Major program elements are documented
to meet the program deliverables.
4. Master Timing Plan
Tool lead time/maker concept
gauge and fixture design concepts
Capacity study complete
Supplier manufacturing facility identified
Major program elements are Major program elements are documented Major program elements are documented
documented to meet the program to meet the program deliverables. to meet the program deliverables.
deliverables.
Tool maker and lead time fixed w/ Tool tryout complete and problems Tool at current design release level
schedule identified tooling issues 100% resolved
Gauge plan complete and approved by Gauges complete and verified Machine/fixture issues 100% resolved
MD Machine/fixtures complete and problems Maintenance PM implemented
Machine/fixture plan complete and identified with countermeasures Set up instructions/process parameters
approved AIAG checklist A-5 or equivalent initiated 100%
and open issues identified. Facility 100% ready per A-5.

5. Facilities, Tool and Gauges

6. Prototype Build Control Plan
7. Prototype Builds
Control plan contains DV test plan
elements and prototype layout
requirements
Prototype build requirements are
documented and agreed with MD
(quantity, dates, lead time)
Prototype build issues fed back into pre-
production control plan.
prototype parts delivered on time at
quality level expected. Build issues have
been addressed.

Surrogate test data submitted to MD DV failures were addressed in the

8. Design Verification Testing
9. Prototype Part Layout and
MDS/MDC Ppk
10. Drawings and Specifications
11. Team Feasibility
Engineering and QA if available
preliminary list of critical characteristics
identified and agreed with MD
Surrogate capability data reviewed with
MD Engineering
CAD data reviewed for feasibility issues
and submitted to MD.
Team Feasibility Commitment has been
reviewed by team and signed off as
DFMEA and corrective actions
incorporated into the design.
DVP&R includes requirements form
all pertinent specifications
layout information complete, process
capability known and can meet drawing
tolerances or actions in place to resolve
Drawings and specifications released and 100% design change implemented 100% design change implemented 100% design change implemented
verified against CAD data
Drawings contain appropriate material
and performance requirements
Drawings contain critical and safety
characteristics
Signed off to current design level Signed off to current design level Signed off to current design level Signed off to current design level

Commitment approved
Initial process flow is complete; used to
develop PFMEA and Control Plan. AIAG
checklist A-6 or equivalent initiated and
12. Manufacturing Process Flow open issues identified with actions
Chart
PFMEA reviewed with Magna Donnelly
and signed. High RPNs have action
plans with timing. AIAG checklist A-7 or
equivalent has been initiated and open
issues identified.
Process Flow complete and AIAG A-6
checklist or equivalent complete with no
open issues. Launch containment is
addressed in flow.
PFMEA complete and approved by
Magna Donnelly. AIAG checklist A-7 or
equivalent complete with no open issues.
Packaging, labeling and shipping are
included in analysis.
Process Flow complete and AIAG A-6 or
equivalent checklist complete with no
open issues
PFMEA complete and approved by
Magna Donnelly. AIAG checklist A-7 or
equivalent complete with no open issues.
PFMEA updated based on PPAP and
early production runs. High RPN and high
severity failures have action plans
completed.
Process Flow complete and AIAG A-6
checklist or equivalent complete with no
open issues
PFMEA complete and approved by
Magna Donnelly. AIAG checklist A-7
complete with no open issues. PFMEA
updated based on early production runs.
High RPN and high severity failures have
action plans completed.

13. Process FMEA


14. Measurement Systems
Evaluation
15. Preproduction Control Plan
16. Production Ramp-up
Schedule
17. Packaging Specifications
(PKG Declaration)
18. Production Control Plan
19. Production Trial Run
20. Production Part Layout
21. Launch Readiness Review
Meeting
22. Preliminary Process
Capability Study
23. Production Validation Testing
24. Boundary Samples
25. Production Part Approval
(PPAP)
26. Production Part Delivery at
MRD
27. IMDS Data Entered into
System
Supplier Management
Approval
* Overall program rating -
GREEN, YELLOW or RED
* Project Manager
* Top Management
Plan for measurement of prototype parts
exists and agreed with MD.
Requirements for Gauge R&R agreed
with MD
Prototype packaging concept approved
with MD
A launch readiness review has been
conducted with MD to review status of
program and deliverables listed above
Gauge R&R complete for prototype as
agreed in phase 4.1. Concerns with
measurement system addressed in
production gauge or fixture design.
Production packaging plan reviewed with
MD
A launch readiness review has been
conducted with MD to review status of
program and deliverables listed above.
AIAG checklist A-4or equivalent initiated
and open issues identified with actions
and timing.
A test plan exists for PV testing including
specifications, tests, sample size,
requirements, and test facility
Design has been reviewed for compliance
to ELV requirements. Concerns have
been reviewed with MD Engineering.
Gauge R&R complete with actual
operators. R&R over 10% has action
plans to address or Magna Donnelly
approval. Gauge instructions exist. A
plan exists for gauge correlation study
with MD incoming inspection.
Pre-production control plan complete and
approved by MD. Launch containment is
documented in plan. AIAG checklist A-8
or equivalent is complete with no open
issues.
Production ramp-up plan defined to
support Magna Donnelly pre-production
and production requirements
Packaging design complete and reviewed
with MD. Testing plan established
Plans exist for production trial run with
trained operators and production process.
AIAG checklist A-4 or equivalent
updated.
Scrap rate and cycle time objectives vs.
plan understood with action plans.
Part layout requirements agreed with MD
- number of pieces, dimensions, etc.
Plans exist to complete on-time.
A launch readiness review has been
conducted with MD to review status of
program and deliverables listed above.
AIAG checklist A-4 or equivalent initiated
and open issues identified with actions
and timing.
A plan exists for completing PpK studies
in support of PPAP
Testing per plan. Plan updated to current
design level
Boundary sample plan reviewed with MD
SQA
Requirement for Appearance Approval
(AAR) is agreed with MD. AAR is
complete if applicable.
IMDS complete. 'Received' number has
been provided to MD
Gauges and instructions updated to
current design level. Gauge R&R
complete with actual operators. R&R
10% or Magna Donnelly approval.
Gauge correlation study complete and
acceptable.
Controls listed in pre-production control
plan have been audited and open issues
identified with actions and timing.
Production schedules fixed in MRP No delivery issues during SOP
systems including raw material and
component releases to support Magna
Donnelly requirements. Requirements
for MDSC are agreed with MD
Testing complete with no open issues. No labeling or packaging issues during
Packaging Declaration submitted and SOP
approved by MD.
Production control plan complete and Process audit complete to control plan to
approved by MD. Launch containment is confirm effective implementation.
documented in plan. AIAG checklist A-8
or equivalent is complete with no open
issues.
Trial run complete with production
process, tooling and equipment.
Problems identified and corrective actions
complete. Scrap rate and cycle time
100% to plan.
Part layout complete and parts match MD
drawing. Dimensional results approved by
MD.
A production readiness assessment is Open issues from Production readiness
planned and the worksheet has been assessment have been resolved
completed and open issues affecting
SOP have adequate plans to meet
program timing.
PpK studies complete and meet PPAP
requirements. Containment plans are in
place and documented on the control
plan for PpK < 1.67 or unstable
processes.
Testing to all material and performance
specifications is complete and product
meets requirements
Boundary samples agreed and signed off
by MD
PPAP status full approval PPAP status full approval
Production shipping schedules No critical delivery occurrences or
established to support MD requirements paperwork errors
Delivery and frequency method agreed
with MD
IMDS complete to current design level.
'Received' number has been provided to
MD
 Program Name: 0
Champion: 0 Worksheet Revision Date:

Key to "Status" symbols: "O" = item meets target (Shift + letter o); "D" = item does not meet target; plans exist; low risk (Shift + d); "C" = item does not meet target with high risk (Shift + c)
Due
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