ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS

PURPOSE
1) 2) 3) 4) To define procedures for new process development , To Develop a cost effective Process to meet Customer timing requirements. To direct company's resources to meet customer requirements To identify problems too early, so that late changes are avoided

Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 1 of 8

SCOPE
Applicable to new process development Applicable to significant process change & significant design modification (If new tooling required or supplied by customer) DEFINITIONS The Cross functional Team for new Process Development and for design process changes is fixed . appointed through an IOM. Development Team will consist of the following functions at the minimum. Engineering Quality Assurance Production Maintenance Purchase Marketing : Programme Manager : Team Member : Team Leader ( CFT Leader) : Team Member : Team Member : Team Member

Amtek group functions and Customer's Representative ( when required by Customer ) will be invited for CFT meeting as and when necessary The person to liaise with Customer and to represent Customer in internal functions will also be identified . CFT Leader can co-ordinate with any other member as and when necessary. As and when necessary , operator will be involved during development.( Ex. C.P. , W.I. )

Record 1) APQP File

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ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS

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Doc.No. : PR/ENGG/01 Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 2 of 8

Secondary Q.A. Engi Mkt

Process Owner : Engineering PROCESS CHART

Start

prod

M.R.

Pur

Related Document

Receive New Product Enquiry with Drawing and or sample.

Enquiry register

Assign Request for Quotation No. to each Drawing and Update RFQ Tracking Sheet.

Quotation

Business decision to process enquiry

No

Regret offer

Yes Formation of CFT Team for project CFT form

Customer / product information & standards given for

NO

Clarify with customer

Yes Refer TGW/TGR record of previous project, Product history for necessary proactive action

Prepare Preliminary BOM , Preliminary Process Flow Chart, Risk Analysis , Manufacturing Team Feasibility, Special Product and Process Characteristics Identified based on Drawing or CRT agreement, Feasibility Review, identify opportunity for Mistake proofing and Review for need of sub supplier

Process flow

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ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS

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Secondary Q.A. Engi Mkt

Process Owner : Engineering PROCESS CHART

A

prod

M.R.

Pur

Related Document

Prepare " Product Costing Sheet", Tooling Costing Sheet. Quote to Customer along with Standard Terms Conditions No
Acceptable

Send to Approval Approval

Costing sheet

Negotiate & Resolve with Customer.

Yes P.O/Tooling Order from Customer 1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point
Need of sub supplier

P.O.

APQP Review Meeting ( Gate 1) Prepare APQP Timing Plan & ensure for adherence.

Review Record

Part Drawing

Receive new drawings & Quality documents from customer

NO
YES

List of customer drawing

Review and check customer data as per check list(AAL/D/CH/01)

Identify & development of sub supplier

Check list

Review of DFMEA , Product history, Quality rating, Drawing Dimns. Clarifications.. Review for Clarification required from customer if any Discuss with customer & get clarification , resolve issue if any.

Start APQP activity of sub supplier as per doc.no AAL/CFT/F/07 . ( Sub supplier APQP Gate Ways )

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Doc.No. : PR/ENGG/01

ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS

Primary

Rev.No. : 02 Rev. dt : 04.07.2008 Page No. : 4 of 8

Secondary Q.A.

Process Owner : Engineering

B

prod

M.R.

Engi

Mkt

Pur

Prepare Amtek Drawing

OK

Get approval from customer & maintain as a Master copy

Pass all drawing specification,signi ficant,characterist ics(CC,SC,PTC,HI C details to supplier for child part development

Amtek Drawing

Master copy drawing file

Put controlled copy stamp & issue to concern dept.

Sample submit to Amtek

Issue Register

Prepare Simulation data for analysis

OK
OK

Not Ok Make changes

REJ

CAD data for tooling

Release Tooling Design to concern

Convey rejected points to sub supplier & take corrective action if any.
PPAP from subsupplier as per level 3 requirement.

Track Five Gateway timing plan & Update GYR Status

K C

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Secondary Q.A. Engi Mkt

Process Owner : Engineering PROCESS CHART Related Document

prod

M.R.

Pur

Review New Equipment, Tooling & Facilities

Identify Special Characteristic

APQP Review Meeting ( Gate 2)

1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point

Special char. sheet

Any Prototype requirements ?

No Yes Develop Prototype Control Plan & Proto samples.

Use PPAP approved part from sub- supplier

Validation of samples for appearance & dimensional aspects ( reliability requirement, if any) & submit to customer. Customer approval

Prepare Process parameters sheet

Process Para. sheet

Review Process Flow Chart

Flow chart

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Secondary Q.A. Engi Mkt

Process Owner : Engineering PROCESS CHART

D

Prod

M.R.

Pur

Related Document

Prepare floor plan

Floor plan

Review PFMEA

Develop Pre-launch / production Control Plan

Control plan

Develop process Quality instructions / Operator instructions

Work instruction

Sampling Trial for casting & machining ( if involved. ) Make corrections if any.

Review Record

Inspection by QA 1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point

APQP Review Meeting ( Gate 3)

Validation of samples (product & process) , confirm parts are meeting dimensional , functional (& reliability requirement, with sub supplier part if any) .

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ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS

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Secondary Q.A. Engi Mkt

Process Owner : Engineering PROCESS CHART

E

Prod

M.R.

Pur

Related Document

Lay out Inspection by QA

Any SPC

No

Yes Develop SPC study Plan Spc study plan

No
Are New MSA

Yes Develop MSA study Plan MSA Plan

Any Production Trial requirements

Dimensional Verification Sample Submission to customer ( With sub supplier part if any ) APQP Review Meeting ( Gate 4) 1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red

Validation record

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ADVANCED PRODUCT QUALITY PLANNING - NEW PRODUCTS

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Secondary Q.A. Engi Mkt

Process Owner : Engineering PROCESS CHART

F

Design

M.R.

Pur

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Customer feedback Corrections if any. PPAP Submission with all applicable documents. (Default level 3 & min. 300 parts unless specified.) Product quality planning summary & sign-off 1) Notify customer for any slippage in PSW Timing plan 2) Initiate recovery action to improve Red point PPAP File Sign off sheet

APQP Review Meeting ( Gate 5)

Review sheet

Track 5000 components or 3 months supplies (whichever is earlier ) for any Concern

Prod. Record

No
Any concerns

Yes Develop, Track Action Plan & review FMEA for high RPN.

Control plan

Any improvement or modification in process after PPAP approval must inform to internal Quality for approval

ECN

Stop

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