APQP Checklist

AQP Checklist -Phase I
Design & Specification Verification, Ease of Manufacture

Supplier: ___________________________________ Page 1A
Part No.: ___________________________________ Description __________________________________
Question Yes No Comment/Action Required Resp Due

1 Is the supplier in receipt of all the latest
issue drawings, product specifications and
process specifications (where applicable)?
2 Is the supplier aware of all critical/sign-
ificant characteristics?
3 Have all pass-through characteristics been

identified ?
4 Has severity ratings been provided by

AP Engineering, to assist
the preparation of the process FMEA?
5 Has the design provided for ease of
manufacture ?
6 Is the supplier aware of the function of the

product & design intent ?
7 Has AP provided the supplier with a project

timing plan identifying key dates to the
supplier ?
AP Supplier Development _________________________ Date ______________________
Supplier Project Manager ______________________________ Revision ___________________

Form: BP19
Project Setup, New Equipment, Tooling & Test Equipment
Supplier: ___________________________________ Page 1B

8 Has the supplier established a project file ?
9 Is there a timing plan in existance at the

supplier ?
10 Has the supplier identified the manufacturing

route ?
11 Has the packaging specification been

determined ?
12 Have lists been prepared identifying:-
a New plant & tooling ?
b New test equipment ?
Supplier Project Manager ______________________________ Revision ___________________ Form: BP19

New Equipment, Tooling and Test Equipment
Supplier: ___________________________________
Page 1C

13 Has tool and equipment design provided for:
a flexible manufacturing systems?
b quick change-overs?
c volume fluctuations?
d mistake proofing?

Form: BP19
Supplier: ___________________________________
Page 1D

14 Has acceptance criteria been agreed upon for:
a) new equipment?
b) new tooling?
c) new test equipment?
15 Will preliminary capability studies be

conducted at tooling or equipment
manufacturers?
16 Has test equipment feasibility and
accuracy been established?
17 Is a preventative maintenance plan

complete for equipment and tooling?
18 Are set-up instructions for new

equipment and tooling complete and
understandable?
19 Will capable gauges be available to
conduct Pp/Ppk studies at supplier's
facility and/or production plant?

Supplier: ___________________________________
Page 1E

20 Does the manufacturing equipment
have sufficient capacity to support
forecasted volumes?
21 Is the testing capacity sufficient to
provide adequate testing?
22 Has provision been made to comply with End

of Life Vehicle legislation ?
Form: BP19
AQP Checklist - Phase II
Floor Plan
Supplier: ___________________________________
Page 2A

1 Does the floor plan identify all
required processes and inspection
points?
2 Have clearly marked areas for all
materials, tools and equipment been
considered for each operation?
3 Has sufficient space been allocated
for all equipment?
4 Are process and inspection areas:

a) of adequate size?
b) adequately lit?
5 Do inspection areas contain necessary

equipment and storage files?
Form: BP19
Floor Plan
Supplier: ___________________________________
Page 2B

6 Are there adequate:
a Staging areas?
b Quarantine areas?
7 Is the process logically laid out to

prevent waste of movement?
8 Are controls adequate to prevent

movement of non-conforming incoming
material to storage or point of use?
9 Are inspection points located to
to prevent shipment of non-conforming
product?
Form: BP19
Floor Plan
Supplier: ___________________________________
Page 2C
10 Have controls been established to

eliminate the potential of contamination
or mix of other products?
11 Have adequate packaging and
despatch facilities been provided?

Form: BP19
Process FMEA
Supplier: ___________________________________
Page 2D

1 Was the Process FMEA compiled
in line with QS9000 guidelines?
2 Have all operations affecting fit,

function, durability, governmental and
safety been considered?
3 Have similar part FMEAs been
considered?
4 Has historical customer complaint

or warranty data been reviewed?
5 Were high severity numbers revised

through a design change?
(where applicable)
6 Have appropriate corrective actions
been planned or taken for high severity
ratings?
7 Have appropriate corrective actions
been planned or taken for high RPN
ratings?
8 Were RPN numbers revised when
corrective actions have been completed?

Form: BP19
Process FMEA
Supplier: ___________________________________
Page 2E

9 Do the effects consider the customer
in terms of subsequent operation,
assembly and product usage?
10 Have the causes been adequately
described in order to encourage
improvements and control?
11 Where detection is defined as the
major control factor, has provision been
made to eliminate the root cause?

Process Flowchart
Supplier: ___________________________________
Page 2F

1 Does the flow chart illustrate the
sequence of production and inspection
stations?
2 Have all the appropriate FMEAs been
used as aids to develop the process
flowchart?
3 Is the flow chart keyed to process and
product checks, as detailed in the control
plan?
4 Does the flow chart describe how the
product will move?
5 Has a pull system optimisation been

considered for this process?
6 Have provisions been made to identify

and activate re-work procedures before
adding further value?
7 Have potential flow/quality problems
due to handling and external processing
been identified and corrected?
Form: BP19
Control Plan
Supplier: ___________________________________
Page 2G

1 Has the Control Plan been prepared using the
correct methodology and objectives( i.e to highlight
method of check, equipment,qty checked)
2 Have all customer concerns been
considered to identify all significant
characteristics, and are they included in the plan?
3 Were all relevant FMEAs employed to
prepare the Control Plan?
4 Are material specifications that require

laboratory verification included in the
Control Plan?
5 Does the Control Plan address all
operations, from incoming material to
packaging and despatch?
6 Are gauging and test equipment
available, as identified by the Control Plan?
Form: BP19
AQP Checklist - Phase III
Process/Product Quality Assurance
Supplier: ___________________________________ Page 3A

1 Has process capability been established for
significant characteristics (I.e >1.67 CP/Cpk )
2 Is there a documented training programme that includes:

a all employees involved with AP products
and processes?
b training matrices for all relevant employees

covering all applicable disciplines?
3 Are all operations covered by process

instructions that are keyed to the Control
Plan?
4 Are operation instructions available
at point of use?
5 Is there a documented TPM plan for the

production equipement in use ?

Form: BP19
Supplier: ___________________________________
Page 3B

6. Do inspection instructions include:
a) easily understood inspection/test requirements?
b) frequency of checks?
c) sample/sub-group sizes?
instructions that are keyed to the Control
Plan?
d) responsibility?
e) method of check?
f) recording/reporting method?
7 Have R & R studies been satisfactorily completed

for all measuring equipment in use ?
Form: BP19
Supplier: ___________________________________
Page 3C

8. Where visual aids are employed are they:
a) available at point of use?
b) authorised as acceptable/unacceptable?
c) dated and current?
d) accessible at point of use?
Form: BP19
Supplier: ___________________________________
Page 3D

9 Is there a procedure to implement,
maintain and establish reaction plans for
SPC charts?
10 Is there an effective root cause analysis
system in place?
11 Have all relevant drawings and/or

specifications been made available at
inspection stations?
12 Are forms/logs available to record
all necessary inspection activity?
13 Have gauges and metrology equipment

been scheduled for routine calibration?
14. Is there a procedure for controlling incoming product that identifies:

a) characteristics to be inspected?
b) frequency of inspection?

Form: BP19
Supplier: ___________________________________
Page 3E

15. Is there a procedure for controlling incoming product that identifies:
c) sample size?
d) designated locations for approved and rejected

product?
e) disposition of non-conforming products

or services?
16 Is there a procedure to identify,

segregate and control non-conforming
product to prevent further added value?
17 Are re-work/repair procedures
available?
18 Is there a procedure to revalidate

re-worked/repaired product?
Form: BP19
Supplier: ___________________________________
Page 3F
19 Is there a system that ensures process
and material traceability?
20 Are periodic despatch audits planned?
21 Has the packaging specification been

approved by AP ?
22 Is there a planned system of internal

quality system audits?
23 What is the actual run at rate ?
Form: BP19

APQP Checklist

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AQP Checklist -Phase I

Design & Specification Verification, Ease of Manufacture

Question Yes No Comment/Action Required Resp Due

3 Have all pass-through characteristics been

4 Has severity ratings been provided by

6 Is the supplier aware of the function of the

7 Has AP provided the supplier with a project

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

9 Is there a timing plan in existance at the

10 Has the supplier identified the manufacturing

11 Has the packaging specification been

12 Have lists been prepared identifying:-

a New plant & tooling ?

b New test equipment ?

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________ Form: BP19

Question Yes No Comment/Action Required Resp Due

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

c) new test equipment?

15 Will preliminary capability studies be

17 Is a preventative maintenance plan

18 Are set-up instructions for new

AP Supplier Development _________________________ Date ______________________

Question Yes No Comment/Action Required Resp Due

22 Has provision been made to comply with End

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

4 Are process and inspection areas:

5 Do inspection areas contain necessary

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

7 Is the process logically laid out to

8 Are controls adequate to prevent

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

10 Have controls been established to

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

2 Have all operations affecting fit,

4 Has historical customer complaint

5 Were high severity numbers revised

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________ Form: BP19

Question Yes No Comment/Action Required Resp Due

5 Has a pull system optimisation been

6 Have provisions been made to identify

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

Question Yes No Comment/Action Required Resp Due

4 Are material specifications that require

AP Supplier Development _________________________ Date ______________________

Supplier Project Manager ______________________________ Revision ___________________

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _ Form: BP19

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _ Form: BP19

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _

AP Supplier Development ___ Date

Supplier Project Manager ____________ Revision _