PLANNING FOR PRODUCT REALISATION (Advanced Product Quality Planning) Overall Plan

Lucas - TVS Engineering

Product Customer Application Type New Product SIA 114 12V 65A General Motors Ltd M 200 Project File Name : Project Coordinator : Project Start Date : Introduction Date : Variant ALT/GMI/008/509 V.Mohan doss Dec 06 SEP 07

Date : 10/07/08 Review No.: 5

Next Review Date:

Team Members V.Mohan doss V.Hari Raghavan P.M.Ganesh L.Harish Kumar S.Madhavan A.S.Kailasanathan S.Ravishankar G.Sadanantham Vijayakumar

Initial VMD VHR PMG HKR SM ASK VN GS VK

Department Engg Engg Marketing Process Quality Methods Purchase Tool room MSE

Remarks

Prototype Build Programme

Build Level Material Required Date Quantity Features ** P.I.S.T. % ** P.I.P.C. %

Fitment Samples

31/01/07

1 No

Proto Samples

Completed

3 Nos

Validation Samples

Completed

5 Nos

DE & SRE Brackets : New Brackets used to suit fitment requirement and to accommodate new Rectifier and regulator design. Rotor, Rectifier Assy & Regulator assy.: Same as PA Hyundai

Pilot lot

Completed

100 Nos

Bulk

Completed

200 Nos

Program

Original Plan Date

Current Plan Date

Closed Date

Responsible Engineer's Initial

Remarks(#) or Assistance Required

APQP Elements
1 Plan and Define Programme 1.1@ Collection of Inputs & Policy clearance: 1.1.1 1.1.2 Customer Enquiry Product Concept
(Application, Launch date/timing, Volume, Product and Test specification, target cost)

Need Date

6/12/2006

6/12/2006

6/12/2006

PMG

11/12/06

11/12/06 13/12/06 20/02/07 05/01/07 20/12/06 Common Document

11/12/06 13/12/06 20/02/07 05/01/07 20/12/06

VMD VMD VMD PMG SM / VMD PMG

1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8

Design & Development Review -0 (Product Concept) Product Policy Clearance Pre Contract Review Check List and Adequacy Review Historical Warranty and Quality Information Joint Review of Quality Management Systems Customer Specific requirements and reference to its technical specification

13/12/06 20/02/07 05/01/07 20/12/06

15/12/06

15/12/06

15/12/06

PMG

1.2.1

Concept Design / Specification

( Design, Quality, Reliability, Durability, Maintainability and Life Targets / Goals)

08/12/06 31/01/07 03/02/07 03/02/07 09/02/07 12/02/07 14/02/07 15/02/07 28/02/07 22/02/07 28/02/07 11/01/07

08/12/06 31/01/07 03/02/07 03/02/07 09/02/07 12/02/07 14/02/07 15/02/07 28/02/07 22/02/07 28/02/07 11/01/07

08/12/06 31/01/07 03/02/07 3/2/2007 9/2/2007 9/2/2007 14/02/07 15/02/07 28/02/07 22/02/07 28/02/07 26/12/06

VMD VMD VMD VMD VMD VMD/HKR VMD/HKR VMD VMD VMD/HKR VMD/HKR VMD

1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8

Concept verification samples & fitment trials Concept FMEA Critical Components list Preliminary Bill of Materials Preliminary routing list Preliminary Process Flow Chart Prel. List of Special characteristics

1.2.9*** Product assurance plan (Proving Plan) 1.2.10 1.2.11 Preliminary List of Tools, Gauges & Facilities Estimate of Product Cost & Tooling Cost

1.2.12@ Design & Development Review-I (Concept Design)

2 Product Design and Development Plan 2.1 2.2 2.3 2.4 2.5 "C" outline drawing and / or Proposal
Detailed Design Packaging standard & Specification 14/12/06 27/12/06 29/12/06 01/01/07 03/01/07 ** For Ford Only 14/12/06 27/12/06 29/12/06 01/01/07 03/01/07 @ Management item 14/12/06 27/12/06 29/12/06 01/01/07 20/08/07 VMD VMD VMD TEAM

Design FMEA Final List of Special Characteristics

JAN-07

VMD
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Form No. L11-80K

*** Activities require micro level timing chart

Program

Original Plan Date 10/01/07 20/04/07 12/01/07 16/12/06 18/01/07 20/01/07 25/04/07 26/01/07 01/05/07 15/01/07 18/01/07

Current Plan Date

Closed Date

Responsible Engineer's Initial

Remarks or Assistance Required

APQP Elements

Need Date

2.6 2.7@ 2.8 2.9 2.10 2.11

Issue of Preliminary drawings Design & Development Review - II (Detailed Design) Prototype control plan "C" Outline Drawing Approval by Customer Prototype Build Programme Proto Type Build Completion

10/01/07 11/01/07 12/01/07 16/12/06 18/01/07 20/01/07 25/04/07 26/01/07 01/05/07 15/01/07 18/01/07

10/01/07 05/06/07 12/01/07 25/11/07 20/05/06 22/05/07 25/08/07 26/01/07 28/08/07 15/01/07 20/03/07

VMD VMD VMD/HKR NVK VMD VMD VMD TEAM VMD NVK VMD

2.12*** Design & Development Verification and Validation Completion 2.13 Team Feasibility Commitment (TFC) Report

2.14@ Design & Development Review III (Proto Type) 2.15 2.16 SEN Design Release (DRN)

3 Process Design and Development 3.1 Manufacturing Process Design Input

( Product design output data, Targets for productivity, process capability and cost, Customer requirements if any, Experience from previous development, Product error proofing methods )

02/02/07

02/02/07

1/4/2007

HKR

3.2 3.3*** 3.4*** 3.5 3.6 3.7 3.8

Manufacturing Planning (Routing) APQP for Suppliers / Sample approvals Material and Supplier Development completion Manufacturing Layout Process Flow Chart Release of new / modified process Specifications Finalising data for quality, reliability, maintainability and measurability

07/02/07 22/02/07 15/04/07 24/02/07 27/02/07 NA 30/04/07 01/03/07 15/03/07 19/03/07 22/03/07 30/03/07 12/04/07 30/04/07 10/05/07 27/03/07 10/05/07

07/02/07 22/02/07 15/04/07 24/02/07 27/02/07 NA 30/04/07 01/03/07 15/03/07 19/03/07 22/03/07 30/03/07 12/04/07 30/04/07 10/05/07 27/03/07 10/05/07

5/4/2007 20/04/07 15/11/07 25/08/07 15/06/07

HKR VN VN VK HKR HKR

30/06/07 15/06/07 15/06/07 20/06/07

HKR HKR HKR HKR VK EXISITING (SAME AS Hyundai)

3.9 3.10 3.11 3.12

Process FMEA Prel. QCPC and Operation Standard (WIN) Final List of Tools, Gauges & Facilities Floor Plan Layout

3.13*** Tool & Gauge Design Completion - (Tool/Gauge drawings) 3.14*** Tools & Gauges Manufacturing Completion 3.15*** Test Eqpt., Facilities & P&M Procurement Completion 3.16 3.17 3.18 List of Process Error Proofing methods Pre launch Control Plan List of rapid detection and feedback of product / manufacturing process non-conformities

20/06/07 20/11/07 20/11/07 13/06/07 13/06/07 15/06/07

HKR HKR HKR HKR HKR HKR

4 Product and Process Validation 4.1 4.2 4.3 4.4 4.5 4.6 4.7*** 4.8@ 4.9 4.10 4.11 Trial Production (Part Level Tryouts) Process Verification / Validation (Component approval) Measurement Systems Analysis Preliminary Process Capability Study Production Trial Run (Run at Rate) Product Grading Product Approval Process (PAP) Design & Development Review - IV (Trial Production) Production Validation Testing Packaging Evaluation Work Instructions and Production Control Plan 4.12*** PSW Sign Off 4.13 4.14 Customer Approval (For Product) Mass Production
15/06/07 20/06/07 12/06/07 15/06/07 20/06/07 12/06/07 30/11/07 10/12/2007 15/12/07 MK NVK TEAM 04/05/07 09/05/07 11/05/07 11/05/07 16/05/07 19/05/07 31/05/07 10/06/07 30/06/07 10/06/07 20/09/07 04/05/07 09/05/07 11/05/07 11/05/07 16/05/07 19/05/07 31/05/07 10/06/07 30/06/07 10/06/07 20/09/07 22/11/07 21/11/07 21/11/07 22/11/07 22/11/07 23/11/07 24/11/07 10/12/2007 24/11/07 24/11/07 5/12/2007 TEAM MK/DBR MK MK DBR MK TEAM VMD VMD VMD HKR

5 Feed Back, Assessment and Corrective Action 5.1@ 5.2 Design & Development Review - V (Mass Production) Quality Planning Sign Off
15/07/07 15/07/07 15/07/07 15/07/07 `` 30/06/08 30/06/08 VMD TEAM

Remarks :

Planned By :
Form No. L11-80K JAN- 07 ** For Ford Only

Approved By: @ Management item *** Activities require micro level timing chart
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