Doc. No.

: QSP:01
SASCO
LOGO Rev. No. : 01
PROCEDURE FOR APQP Date : 04.04.2016

1. Purpose:

To establish a procedure for Manufacturing Process Design & Development and to ensure that the new product
development activities are carried out in line with customer requirements and reduce the lead time of the
development continually. The Advanced Product Quality Planning procedure (APQP) accompanies the
development of a product and is intended to ensure that the supplier meets all of the customer's requirements on
time.

2. Scope:

Applicable to all new part (Maru-A/Critical parts, Functional, General) development, ECN implementation.

3. Responsibility:

Overall responsibility for implementation of this procedure lies with PLANT HEAD and HOD-QA whereas he is assisted by
Section Incharge.

4. System:

Prepared By : Approved By :
 Doc. No. : QSP:01
SASCO
LOGO Rev. No. : 01
PROCEDURE FOR APQP Date : 04.04.2016

Sl. Responsibilit
Activity Input Output
No. y
1 PHASE – I

Received Part Drawing / Standard from Customer Part drawing / Review of

end. After received part drawing & standard review standard / Samples Customer Input Plant Head
of customer inputs & material specification.

2 Preliminary Listing of Critical Characteristic. Part Drawing / List of Critical Plant Head
Standard Characteristic.

3 Prepare Initial Feasibility & Risk Analysis. List of Critical Feasibility & Risk Plant Head
Characteristic& Analysis
Drawings, CSR

4 If Initial Feasibility & Risk Analysis not Feasible, Feasibility & Risk Feasibility & Risk Plant Head
reply to customer for the same. Analysis Analysis Report

5 If Initial Feasibility & Risk Analysis Feasible Feasibility & Risk Quotation Head Mkt.
prepares Quotation, discuss and take approval from Analysis (Customer special
top management and send to customer formate)

6 If required, cost negotiation and spec. meeting (if

necessary) shall be done with the customer for the LOI & Purchase Order Go to Dev. Deptt. Head Mkt.
same and Receive LOI / Purchase Order to Customer
and go ahead for development department.

7 If LOI & Purchase Order is Feasible, Review of LOI & Purchase Order Review of Phase–I Plant Head
Phase – I Activities. Activity (MOM)
Phase – I Activities feedback give to Plant Head and
review required within two week.

Prepared By : Approved By :
 Doc. No. : QSP:01
SASCO
LOGO Rev. No. : 01
PROCEDURE FOR APQP Date : 04.04.2016

PHASE – II& PHASE – III (Product & Process

Design and Development.
8 Prepare Development Time line Plan with clearly
defined responsibility of CFT Team and target date
and also prepare the responsibility matrix.
Responsibility Matrix shall explain the Cross
Function team as below.
CFT Members:-Mkt, Engg., Dev, QA, Production,
Store, Purchase, Dispatch, Tool room.
Development plan Activity Review Frequency shall
be once in a week by CFT and once in month by top Feasibility Study, Risk Development Plan Dev Head
management or customer specific. Analysis, Contract Responsibility &CFT
Responsibility Matrix shall contain the below (Micro Review & LOI & Tool Matrix with CFT
plan activity) activities during preparation of time Go, Purchase Order, Team, Micro plan,
line plan. CSR Project Review
a) TOOL & FIXTURE PREPARATION record.
b) EQUIPMENT / MACHINE PREPARATION
c) GAUGE \ INSP EQPT. PREPARATION
d) ADVANCE DESIGN CHANGE INFORMATION
e) PAST TROUBLE, RE-OCCUR PREVENTION
VERIFICATION
f) SPEC TEST VERIFICATION PLAN
g) MIS – P (IF APPLICABLE)
h) CTQ PARAMETERS IDENTIFICATON
i) MAKING PROCESS FLOW CHART
j) PROCESS FMEA VERIFICATION PLAN
k) MAKING PRE LAUNCH CONTROL PLAN
l) TIER 2 READYNESS
m) LOCAL/IMPORTED RAW MATERIAL PLAN
n) PACKAGING TRIAL PLAN
o) CAPACITY VERIFICATION PLAN
p) FLOOR PLAN LAYOUT
q) CHARACTERISTICS MATRIX
r) PRELIMINAY PROCESS CAPABILITY STUDY
PLAN
s) MEASUREMENT SYSTEM ANALYSIS PALN
t) OTHER CUSTOMER SPECIFIC …ETC.

9 At the time of Development time line preparation, it Development Plan

shall be ensured that all the past problem related to Resp. Matrix with Past Problem Head Dev
similar product has been taken care. CFT Team, Micro review record
plan,Project Review
record.
Development Plan
10 Prepare Listing of Jig, Fixtures, Gauges, Equipment,
Machines &Tools. Do List of Jig, Head Dev.
Fixture,Gauge,
Equipment,
11 Prepare B.O.P & Part Drawing (If Required), and get Machines & Tools
Approval if required. Approved Customer
After Approval Issue Drawing / Standard to Concern input N.P.D&
supplier. BOM, BOM, Drawings Purchase
NPD

Prepared By : Approved By :
15
 Doc. No. : QSP:01
SASCO
LOGO Rev. No. : 01
PROCEDURE FOR APQP Date : 04.04.2016

PHASE – IV (Product and process Validation)

12 Conduct Significant Product run (300Parts / 8 Hrs) or Prelaunch Control Production Production
Customer specific. Conduct MSA Study and Process Plan, FMEA, PCS, Control plan, & NPD
capability study (If Required) Inspection Standard Capacity
Conduct internal & External packaging evaluation confirmation,
Prepare the production control plan SPC, MSA, Spec NPD
Confirm the PFMEA implementation results Test Results, &
Confirm the Spec test Results
Layout inspection Production
Conduct Layout inspection for 05 Samples Or
Customer Specific.

13 PSW Submission to Customer with PPAP Level III or

Customer Specific requirement.
Production Control Level III PPAP Or NPD
plan, Capacity as per customer
confirmation, SPC, requirement
MSA, Spec Test
Results, Layout
inspection
14 For initial supply control, refer the procedure of initial
supply control QSP:29 Level III PPAP Or as Status of targets NPD
per customer and process
requirement Capability
15 After PSW Sign off with the customer, Start
Rampup Activities (Review of targets & Monitoring of Status of targets and Signed PSW NPD
Process Stability) process Capability

16 And Conduct the review of quality management

system. Signed PSW QMS Review QA &
QMS
17 As per initial supply control procedure Conduct
Review of targets &Monitoring of Process Stability Level III PPAP Or as APQP Check list Head Dev,
and confirm the same till 3 month/500 parts (whichever per customer
is more) and then conduct the Quality Planning Sign APQP Sign off QA &
requirement, Status of Production
off with production & Quality. initial supply record

Customer input & Engineering

18 In case of any ECN raised from customer, refer the Drawing
APQP Matrix. Review of ECN within 2 Working Change Note Head NPD
Weeks Or as per Customer Requirement after
Receiving from Customer. Feasibility study of Change
Point.

19 Update relevent Documents like Control Plan SOP, Updated Head NPD
Inpection Standard./ Etc if required and submit to Old Documents Documents
Customer & Update the Revision Status of documents
in Master list of documents.

Prepared By : Approved By :
 Doc. No. : QSP:01
SASCO
LOGO Rev. No. : 01
PROCEDURE FOR APQP Date : 04.04.2016

Sl. Responsibilit
Activity Input Output
No. y
PHASE - V

20 Get feedback from customer / communicate to Feedback report Action Plan Head NPD
customer for further action at every phase.

21 After PSW Sign off started Ram pup Activities PCS, SPC Plan &
(Review of targets & Monitoring of Process SOP
Stability)

22 If Completion Ok, then release S.O.P, FMEA for All Targets Monitoring Head NPD
Production process,

23 If Completion is not ok, then re Start Ram pup Monitoring PCS& S.O.P
Activities (Review of targets & Monitoring of Production Head NPD
Process Stability)

24 Review learning of Project (Things gone Completion Results Monitoring Head NPD
wrong/things gone right) &
Review of Phase – V Activities.
Phase – V Activities feedback give to Plant Head and
review required within two week
APQP file
25 Future reference. Head NPD
APQP project file has been completed as per the
checklist & signoff Quality issue
26 Smooth part
APQP file document has been reviewed once in a production CFT with
year or when any customer complaint / major Plant Head.
process issue has been noticed.

Prepared By : Approved By :
 Doc. No. : QSP:01
SASCO
LOGO Rev. No. : 01
PROCEDURE FOR APQP Date : 04.04.2016

5. Formats:-
6.1 APQP Document List
6.2 APQP/Part Development Timing plan F-DEV-01
6.3 Responsibility Matrix F-DEV-24
6.4 Micro Plan F-DEV-25
6.5 Part Development Problem History F-DEV-26
6.6 Process Flow Diagram F-Dev-06
6.7 PFMEA F-DEV-07
6.8 Control Plan F-DEV-08
6.9 Packing Standard –as per customer specific
7.0 Peak Production Verification Trail(PPVT) F-DEV-02
7.1 Initial Supply Control Sign Off F-DEV-03
7.2 ECN F-DEV-04
7.3 List of special characteristics F-DEV-05
7.4 Product Quality Planning summary & Sign off F-DEV-09
7.5 Part Submission Warrant F-DEV-10
7.6 Apperance Approval Report F-DEV-11
7.7 Material Test Plan Certificate/Report F-DEV-12
7.8 Initial Supply Control- Process Tag F-DEV-13
7.9 PFMEA Review Plan F-DEV-15
8.0 Contract Review Form F-DEV-16
8.1 Costing Sheet F-DEV-17
8.2 PDCA Cycle F-DEV-18
8.3 Checking Aids F-DEV-19
8.4 Engineering Change Request F-DEV-20
8.5 Risk Analysis F-DEV-21
8.

8.9
9.0
9.1 Defects Items Expected F-DEV-30

01 04/04/2016 Procedure update as per MSIL requirements

Rev No. Date Details of Amendment

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