APQP Project Management Checklist

APQP Product Development System (PDS) - Project : Project Management position
Concept Project Approval Prototype Pilot SoP
Phase 0.0 Project Initiation Phase 1.0 Plan and Define Project Phase 2.0 Product Design and Development Phase 3.0 Process Design and Development Phase 4.0 Product and Process Validation Phase 5.0 Feedback, Assessment and Corrective Actions Project Controlling and other supporting PDS processes
Handover Period SoP +/- 90 days
MR0 PS0
MR1 PS1
MR2 PS2
MR3 PS3
MR4 PS4
MR5
Go / No-Go
Model and Drawing Design Review
Manufacturing Facility Design Approval
Design Freeze
Tooling Design Freeze
Run@Rate
Final Report
Management Review
Phase Sign-Off
Handover Period SoP +/- 90 days
Production Support Production Controlling MR5 PS5
ing PDS processes
Final Report
Advanced Product Quality Planning ( APQP) Checklist

Start Date: Plant Name: Plant Location: Plant Code: Risk Assessment Status: New: Other Risks
Team Members
High Site
Medium Technology
Low Process
Date: Part Number: Part Name: Specification / Drawings No: Version: Plant:
Tel/Mobile No E-mail
Company / Responsibility
Mr. Robbie Howarth
APQP Project Adviser Plant Project Team Leader Chief Engineer (R & D) Project Team Member (Maintenance) Project Team Member (Purchasing) Project Team Member (Finance) Project Team Member (Sales) Project Team Member (Production Operator) Project Team Member (Quality) Project Team Member (Production Supervisor/Team Leader)
Material Required Date Quantity Special Characteristics Comments
Build Level Prototype
APQP Elements
G Y R
Project Due Date
Internal Completion Date Completion Date Champion Name
Document Revision Date & Rev. Comments / Action Plan
Phase 0.0 Project Initiation

0.1 0.2 0.3 0.4 0.5 0.6 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Request for Quotation (RFQ) Registration Quotation Kick-Off and Team Setup Formulation of Quote FEP plus & Customer Specific Quote Handover Quote Phase 0 Gate Review & Sign Off Project Kick-Off and Set Up Project Folder Define Financial Baseline Refine Preliminary Design Chacteristics Refine Preliminary Process Flow and Manufacturing Facilities Preliminary Tooling and Manufacturing Facilities Plan Corrective Actions Phase 1 Gate Review & Sign Off
Ops Team
Phase 1.0 Plan and Define Project
Ops Team
Phase 2.0 Product Design & Development

2.1 DFMEA 2.2 DFMA 2.3 Preliminary PFMEA 2.4 Design Verification Plan & Report 2.5 CAD Model & Simulations 2.6 "Make or Buy" Evaluation - Design Review (Model and Drawing) 2.7 Assessment and Selection of Suppliers 2.8 Prototype Control Plan 2.9 Production Process Flow Chart 2.10 Prototype Construction and Review 2.11 Engineering Drawings - Design Review (Design Freeze) 2.12 Datebase 2.13 Corrective Actions 2.18 Phase 2 Gate Review & Sign Off
Ops Team
Phase 3.0 Process Design and Development

3.1 PFMEA 3.2 Manufacturing Facility Design 3.3 Pre-Launch Control Plan 3.4 Measurement Systems Analysis Plan 3.5 Production Equipment Safety 3.6 Process Instructions and Training Plan 3.7 Manufacturing Facility Design Approval 3.8 Tool Design and Tool FMEA 3.9 Verification of Tool Bill of Parts 3.10 Verification of Part Dimensions 3.11 Verification of Tool Functionality 3.12 Tool Design Review 3.13 Packaging Specification 3.14 Corrective Actions 3.15 Phase 3 Gate Review & Sign Off
Ops Team
Phase 4.0 Product and Process Validation

4.1 Gauge R & R 4.2 Gauge Certification and Registration 4.3 Training Builds 4.4 Tool Tryout 4.5 Tool Life Deviation 4.6 Production Approval for Tool & Manufacturing Facilities 4.7 DVP & R Concluded 4.8 Production Control Plan 4.9 Production Part Approval Process (PPAP) 4.10 Internal Run@Rate 4.11 Production System Audit 4.12 Run @ Rate 4.13 Corrective Actions 4.14 Phase 4 Gate Review & Sign Off
Ops Team
Phase 5.0 Feedback, Assessment and Corrective Actions

5.1 Handover of Project Responsibility to Production 5.2 Management Review and Phase 5 Sign-Off 5.3 Launch Support (CIP) 5.4 Phase 5 Gate Review & Sign Off Overall Project Phases Review & Sign Off
- COMMENTS
Ops Team UM/FWW
Required Form
63423512.xls.XLS
APQPSTAT (UK Version) 5/51
Rev. Date: 7/21/06
Report No.
Advanced Product Quality Planning

Status Report
Quality Status
System Unsatisfactory Satisfactory Other Previous Rating and % Percentage Conformance
Date:
Attendees (Supplier)
Department
Attendees (LT)
Department
2010
J Prototype Programme Key Dates Phase 0.0 Project Initiation 0.1 Request for Quotation (RFQ) Registration 0.2 Quotation Kick-Off and Team Setup
Phase 0.0
2011
Sun Clause A S O N D J F M A M J J A S O N D Next APQP Date
Functional Job 1
Status
Action Required
0.1 0.2 0.3 0.4 0.5
0.3 Formulation of Quote 0.4 FEP plus & Customer Specific Quote 0.5 Handover Quote 0.6 Phase 0 Gate Review & Sign Off
Phase 1.0 Plan & Define Project

1.1 Project Kick-Off and Set Up Project Folder 1.2 Defrine Financial Baseline 1.3 Refine Preliminary Design Chacteristics 1.4 Refine Preliminary Process Flow and Manufacturing Facilities 1.5 Preliminary Tooling and Manufacturing Facilities Plan 1.6 Corrective Actions 1.7 Phase 1 Gate Review & Sign Off 2.1 DFMEA 2.2 DFMA
1.1 1.2 1.3 1.4 1.5 1.6 1.7

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.1 2.11 2.12 2.13 2.14
2.3 Preliminary PFMEA 2.4 DVP & R 2.5 CAD Model & Simulations 2.6 "Make or Buy" Evaluation - Design Review (Model and Drawing) 2.7 Assessment and Selection of Suppliers 2.8 Prototype Control Plan 2.9 Production Process Flow Chart 2.10 Pfrototype Construction and Review 2.11 Engineering Drawings - Design Review (Design Freeze) 2.12 Datebase 2.13 Corrective Actions 2.14 Phase 2 Gate Review & Sign Off
Phase 3.0 Process Design & Development 3.1 PFMEA 3.2 Manufacturing Facility Design
Phase 3.0 Process Design & Development 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.11 3.12 3.13 3.14
3.3 Pre-Launch Control Plan 3.4 Measurement Systems Analysis Plan 3.5 Production Equipment Safety 3.6 Process Instructions and Training Plan 3.7 Manufacturing Facility Design Approval 3.8 Tool Design and Tool FMEA 3.9 Verification of Tool Bill of Parts 3.10 Verification of Part Dimensions 3.11 Verification of Tool Functionality Tool Design Review 3.12 Packaging Specification 3.13 Corrective Actions 3.14 Phase 3 Gate Review & Sign Off
Phase 4.0 Product & Process Validation 4.1 Gauge R & R 4.2 Gauge Certification and Registration
Phase 4.0 Product & Process Validation 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.1 4.11 4.12 4.13 4.14
4.3 Training Builds 4.4 Tool Tryout 4.5 Tool Life Deviation 4.6 Production Approval for Tool & Manufacturing Facilities 4.7 DVP & R Concluded 4.8 Production Control Plan 4.9 Production Part Approval Process (PPAP) 4.10 Internal Run@Rate 4.11 Production System Audit 4.12 Run @ Rate 4.13 Corrective Actions 4.14 Phase 4 Gate Review & Sign Off
Phase 5.0 Feedback, Assessment and Corrective Actions 5.1 Handover of Project Responsibility to Production
Phase 5.0 5.1 5.2 5.3 5.4
5.2 Management Review and Phase 5 Sign-Off 5.3 Launch Support (CIP) 5.4 Phase 5 Gate Review & Sign Off Overall Project Phases Review & Sign Off
C Completed O On Schedule Issued By: Issued Date: Issue No.: Page 1 of 10 Latest Date : 07/21/2011
B Behind schedule with no catch up plan
Issued By: Issued Date: Issue No.:
Page 1 of 10
Latest Date : 07/21/2011
ormance
ment
xt APQP Date
tion Required
Page 1 of 10
Page 1 of 10

Ausgabedatum: Hersteller: Ort: Neumayer Tekfor Hausach Datum berarbeitungsnummer: # Projekt / Teilenummer: Spezifikation / Zeichnungsnr.: nderungsstand: Werk:
Fax
Formularnummer: Anlage zu EW 017 10/27/2008 6953.49.00 3 Hausach

e-mail
Neu:
Ort Risiko
Technologie x
Prozess x
Team Mitglieder
Firma / Ttigkeit
Hr. Dr.Koerner Hr. Roser Hr. Schmid
Projektleiter Projektmanagement Industrialisierung
ekkehard.koerner@neumayer-tekfor.com tobias.roser@neumayer-tekfor.com erwin.schmid@neumayer-tekfor.com
Required Date
Quantity
Special Characteristics
Comments
APQP Elements
G Y R
Projekt FlligkeitsDatum
Internes Soll Datum
erledigt Datum
Champion Name
Document Revision Date & Rev.
Bemerkungen / Aktionsplan

0.1 0.2 0.3 0.4 0.5 0.6 1.1 1.2 1.3 1.4 1.5 1.6 1.7 RFQ (Request for Quotation) Registration Quotation Kick-Off and Team Setup Formulation of Quote FEP plus & Customer Specific Quote Handover Quote Phase 0 Gate Review & Sign Off Project Kick-Off and Set Up Project Folder Defrine Financial Baseline Refine Preliminary Design Chacteristics Refine Preliminary Process Flow and Manufacturing Facilities Preliminary Tooling and Manufacturing Facilities Plan Corrective Actions Phase 1 Gate Review & Sign Off
Ops Team
Ops Team

2.1 DFMEA 2.2 DFMA 2.3 Preliminary PFMEA 2.4 DVP & R 2.5 CAD Model & Simulations 2.6 "Make or Buy" Evaluation - Design Review (Model and Drawing) 2.7 Assessment and Selection of Suppliers 2.8 Prototype Control Plan 2.9 Production Process Flow Chart 2.10 Pfrototype Construction and Review 2.11 Engineering Drawings - Design Review (Design Freeze) 2.12 Datebase 2.13 Corrective Actions 2.18 Phase 2 Gate Review & Sign Off
Ops Team

3.1 PFMEA 3.2 Manufacturing Facility Design 3.3 Pre-Launch Control Plan 3.4 Measurement Systems Analysis Plan 3.5 Production Equipment Safety 3.6 Process Instructions and Traininbg Plan 3.6 Manufacturing Facility Design Approval 3.7 Tool Design and Tool FMEA 3.8 Verification of Tool Bill of Parts 3.9 Verification of Part Dimensions 3.10 Verification of Tool Functionality Tool Design Review 3.11 Packaging Specification 3.12 Corrective Actions 3.13 Phase 3 Gate Review & Sign Off
Ops Team

4.1 Gauge R & R 4.2 gauge certification and Registration 4.3 Training Builds 4.4 Tool Tryout 4.5 Tool Life Deviation 4.6 Production Apporval for Tool & Manufacturing Facilities 4.7 DVP & R Concluded 4.8 Production Control Plan 4.9 PPAP 4.10 Internal Run@Rate 4.11 Production System Audit 4.12 Run @Rate 4.13 Corrective Actions 4.14 Phase 4 Gate Review & Sign Off
Ops Team

- COMMENTS
Ops Team UM/FWW
Required Form
63423512.xls.XLS
APQPSTAT (German Version) 10/51
Rev. Date: 7/21/06

Fax

e-mail
Neu:
Ort Risiko
Technologie x
Prozess x
Team Mitglieder
Firma / Ttigkeit
Required Date
Quantity
Comments
APQP Elements
G Y R
Internes Soll Datum
erledigt Datum
Champion Name

Ops Team
Ops Team

Ops Team

Ops Team

Ops Team

- COMMENTS
Ops Team UM/FWW
Required Form
63423512.xls.XLS
APQPSTAT (Italian Version) 11/51
Rev. Date: 7/21/06

Fax

e-mail
Neu:
Ort Risiko
Technologie x
Prozess x
Team Mitglieder
Firma / Ttigkeit
Required Date
Quantity
Comments
APQP Elements
G Y R
Internes Soll Datum
erledigt Datum
Champion Name

Ops Team
Ops Team

Ops Team

Ops Team

Ops Team

- COMMENTS
Ops Team UM/FWW
Required Form
63423512.xls.XLS
APQPSTAT (Brazil) 12/51
Rev. Date: 7/21/06

Responsibilities
APQP Advisor/Facilitator
R
Phases
Department
Customer
Person

Phase 0 0.1 0.2 0.3 0.4 0.5 0.6 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Request for Quotation (RFQ) Registration Quotation Kick-Off and Team Setup Formulation of Quote FEP plus & Customer Specific Quote Handover Quote Phase 0 Gate Review & Sign Off Project Kick-Off and Set Up Project Folder Defrine Financial Baseline Refine Preliminary Design Chacteristics Refine Preliminary Process Flow and Manufacturing Facilities Preliminary Tooling and Manufacturing Facilities Plan Corrective Actions Phase 1 Gate Review & Sign Off
C C C C C C
R
C I

I I I I I R C C C C C C R C
Phase 1

R R I C C A R R R C C C C C C C C C C C C C R R C
Phase 2
R R R
Phase 3.0 Process Design & Development

3.1 PFMEA 3.2 Manufacturing Facility Design 3.3 Pre-Launch Control Plan 3.4 Measurement Systems Analysis Plan 3.5 Production Equipment Safety 3.6 Process Instructions and Training Plan 3.6 Manufacturing Facility Design Approval 3.7 Tool Design and Tool FMEA 3.8 Verification of Tool Bill of Parts 3.9 Verification of Part Dimensions 3.10 Verification of Tool Functionality Tool Design Review 3.11 Packaging Specification 3.12 Corrective Actions 3.13 Phase 3 Gate Review & Sign Off
C C C C C C C C C C C C C C R C
Phase 3
R A
Phase 4.0 Product & Process Validation

4.1 Gauge R & R 4.2 Gauge Certification and Registration 4.3 Training Builds 4.4 Tool Tryout 4.5 Tool Life Deviation 4.6 Production Approval for Tool & Manufacturing Facilities 4.7 DVP & R Concluded 4.8 Production Control Plan 4.9 Production Part Approval Process (PPAP) 4.10 Internal Run@Rate 4.11 Production System Audit 4.12 Run @ Rate 4.13 Corrective Actions 4.14 Phase 4 Gate Review & Sign Off
C C C C C C C C C C C C C R
Phase 4

Phase 5 5.1 Handover of Project Responsibility to Production 5.2 Management Review and Phase 5 Sign-Off 5.3 Launch Support (CIP) 5.4 Phase 5 Gate Review & Sign Off Overall Project Phases Review & Sign Off
Responsible Accountable Consulted Informed R A C I C C C C R R
Robbie Howarth
APQP PROJECT DEVELOPMENT SYSTEM APQP Document Change List No: 1 Date Doc # Change Reason for Change
Title
Page #
APQP Project Timetable
Open Issues - Action Plans

APQP Phase & Element Date Description of Concern Actions Taken / Implemented Name of Responsibility Completion Date Status
63423512.xls.XLS
Open Issues 17/51
Rev. Date: 7/21/06
Meeting Log
Date of APQP Meetings Name of Participant Kick-off 1 2 3 4 5 6 7 8 9
Optional Form
63423512.xls.XLS
Meeting Log 18/51
Rev. Date: 7/21/06
Team Feasibility Commitment

Feasibility Considerations
Our product quality planning team has considered the following questions. The drawings and/or specifications provided have been used as a basis for analyzing the ability to meet all requirements. All "no" answers are supported with attached comments identifying our concerns and/or proposed changes to enable the organisation to meet specified requirements.
Plant Customer / Product Date Revision level: Customer: Part Name: Date: Part No:
Requirements
Comments/Actions Required
Task Status
Resp. Initials
Due Date
Is product adequately defined (application requirements, etc.) to enable feasibility evaluation? Can Engineering Performance Specifications can be met as written?
Task Not Complete
Task Not Complete
Can product can be manufactured to tolerances as specified on drawing and in accordance with the DBL and Lastenheft? Is there adequate capacity to produce product?
Task Not Complete
Task Not Complete
Product can be manufactured with Cpk's that meet minimum 1.33 requirements (1.67 on safety related items). Product can be manufactured with Cpk's that meet minimum 1.33 requirements (1.67 on safety related items). Where statistical process controls is(are) used on similar products, the processes are stable and in control. Where statistical process controls is(are) used on similar products, Cpk's are greater than 1.33 (1.67 on safety related items). Lessons learned from similar products have been reviewed by the team. How? When? The Suppliers APQP Team has reviewed and signed off the Feasiblity Commitment Checklist.
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
10
Task Not Complete
Conclusion Feasible Feasible Not Feasible FALSE Product can be produced as specified with no revisions FALSE Changes recommended or open issues need addressed (see attached) FALSE Design revision required to produce product with the specified requirements
0% TOTAL PERCENTAGE COMPLETE 111% TOTAL PERCENTAGE INCOMPLETE
Approval
Team Leader/Date:
Quality Engineer / Date:
Tooling Engineer/Date:
Manufacturing Engineer / Date:
Industrial Engineer/Date:
General Manager / Date:
Material Manager / Purchasing / Date:
Account Manager / Date:
Production Supervisor / Date:
APQP Engineer / Date:
Title:
Title:
DFMEA Please place a copy of the DFMEA in this tab
Commercial Checklist
Plant Customer / Product
Date
Requirements
Task Status Task Not Complete
Resp. Initials
Due Date
1 2
The Letter of Intent has been signed by NTG and the supplier.
Task Not Complete
The Tooling P. O. has been received.

Task Not Complete
The Manufacturing Location has been chosen.

Task Not Complete
Annual Volume has been determined.

Task Not Complete
A project timeline has been developed & submitted to the customer.

Task Not Complete
All PPAP requirements are documented and understood to allow for Customer payment of tooling and/or equipment. Sufficient money is budgeted for the purchase of gages, or other required verification equipment (measurement systems & testing equipment). There are no additional costs required beyond the quotation that need to be discussed with the customer.
Task Not Complete
Task Not Complete
Task Not Complete 9
The latest Engineering change is quoted and submitted to Purchasing.

Task Not Complete
10
The latest Engineering change is to all agreed ESI (Early Supplier Involvement) specifications (I.e. test, material, datum schemes, tolerances, etc.) All changes to date have been agreed to by Schefenacker Engineering and Purchasing. The customers Supplier Quality Manual and its related expectations/measurements have been completely reviewed, understood and agreed to.
Task Not Complete
11
Task Not Complete
12
TOTAL PERCENTAGE COMPLETE TOTAL PERCENTAGE INCOMPLETE
0% 100%
Design Information Checklist

Plant Customer / Product Date
Requirements 1
Resp. Initials
Due Date
Dimensions or properties that affect fit, function and durability have been identified.
Task Not Complete
Key Quality Characteristics (KQC) and Key Process Characteristics (KPC) have been selected and documented. All known customer concerns have been identified to facilitate the selection of KQC's and KPC's. Sufficient control points and datum surfaces are identified to design functional gages.
Task Not Complete
Task Not Complete 4
Drawing tolerances are compatible with accepted manufacturing standards.

Task Not Complete
All requirements specified can be evaluated using known inspection techniques.

Task Not Complete
Specified materials are compatible with the durability requirements in the identified environment.
Task Not Complete 7
The intended material suppliers are on the customer approved list.

Task Not Complete
Material suppliers will be required to provide certification with each shipment.

Task Not Complete
Material characteristics requiring inspection have been identified.

Task Not Complete
10
Critical material characteristics can be checked by the supplier.

Task Not Complete
11
All outside testing laboratories used will be accredited.

Task Not Complete
12
Material handling impact on the design has been considered.

Task Not Complete
13
Material storage impact on the design has been considered.

Task Not Complete
14
Environmental concerns with the materials or process have been considered.

Task Not Complete
15
The bill of material is complete.

Task Not Complete
16
The DFMEA is available for review.

Task Not Complete
17
Specified raw materials (example: steel) are commercially available in country of manufacture.
Task Not Complete 18
All pending Engineering changes that may postpone the start of tooling, fixturing, raw material purchases, etc have been accounted for and implemented into the timing with no detrimental timing changes.
Task Not Complete
19
The product test plan is complete and approved by SVS NPI team.
Task Not Complete
20
The supplier has copies of the performance and material specifications

0% 95%
Key Quality Characteristics
Please list the Key Quality Characterstics and methods to be used to monitor in this area
Tooling Checklist
Requirements 1
Resp. Initials
Due Date
Tool sources have been identified.

Task Not Complete
The tool design has provided for quick change if necessary.

Task Not Complete
The tool design has provided for volume fluctuations, where applicable.
Task Not Complete
Mistake proofing needs were incorporated in the tool design.

Task Not Complete
Key quality characteristics and key process characteristics were considered in the design of the tooling.
Task Not Complete 6
Process safety was considered in the design of the tooling.

Task Not Complete
The material specifications, including physical and chemical properties of the material to be processed in the tool, were considered in the design of the tooling.
Task Not Complete 8
The Tooling Design has been completed.

Task Not Complete
The supplier has approved the tool design.

Task Not Complete
10
The Tooling has been kicked off.

Task Not Complete
11
A timeline with sufficient tooling detail has been submitted to the customer.
Task Not Complete
12
Tool Tracking Sheets have lists prepared identifying all new tooling.
Task Not Complete
13
The supplier and tooling contractor have a written acceptance criteria for new tooling.
Task Not Complete
14
Preliminary capability studies or a sample run-off will be conducted at the tooling manufacturer.
There is a preventive maintenance plan for tooling.

Task Not Complete
16
A spare parts list has been developed.

Task Not Complete
17
Setup instructions for new tooling are complete and understandable.

Task Not Complete
18
Parts submitted from tools to Painter and SVS for evaluation and buy-off (painted product). Tooling Preventive Maintenance established and approved by SVS and Painter (painted product).
Task Not Complete
19
Allowable limits for burrs, flash, and trimming are documented and understood.
Task Not Complete
21
Standards for Class-A , B, C, and D surfaces are documented and understood.

Task Not Complete
22
Certified checking fixtures will be available at the tool source for part run-offs.
Task Not Complete
23
Parting lines and gate locations are documented and understood (molded parts).
0% 100%
Should we distinguish between our tools we give suppliers and tools they make? Or add statement for tools they make?
Process Flow Chart Checklist

Requirements 1
Resp. Initials
Due Date
The process flow chart illustrates the production sequence, production methods and inspection stations including all incoming components.
Task Not Complete 2
The DFMEA was used to develop the process flow chart.

Task Not Complete
The operation number on the flowchart will be carried over to the control plan and the Process FMEA. Provisions have been made to identify and inspect reworked products before being used. The rework and requalification loop is illustrated on the flowchart.
Task Not Complete
TOTAL PERCENTAGE COMPLETE TOTAL PERCENTAGE OPEN
0% 100%
Process FMEA Checklist

Requirements
Resp. Initials
Due Date
1
2
If applicable, the DFMEA was used to help develop the PFMEA. The Process FMEA was prepared using the AIAG guidelines for severity, detection and occurence.
Task Not Complete
Task Not Complete 3
The PFMEA was developed using the Process Flow Chart.

Task Not Complete
All the operations affecting fit, function, durability, governmental regulations, and safety have been identified.
Task Not Complete 5
Experience with similar parts and lessons learned were considered for the PFMEA.
Task Not Complete
Historical plant returns, campaign and warranty data were considered for the PFMEA.
Task Not Complete
Appropriate corrective actions have been planned or taken for high risk priority numbers.
Task Not Complete 8
Appropriate corrective actions have been planned or taken for high severity numbers.
Task Not Complete
Appropriate corrective actions have been planned or taken for high dectection numbers. Appropriate corrective actions have been planned or taken for high occurence numbers.
Task Not Complete
10
Risk priority numbers were revised when a corrective action was completed.
Task Not Complete
12
High severity numbers were revised when a design change was completed.
Task Not Complete
13
Causes have been described in terms of something that can be fixed or controlled.
Task Not Complete
14
Where detection is the major factor, provisions have been made to control the cause prior to the next operation.
0% 100%
PFMEA
Please place a copy of the PFMEA in this area
Equipment Checklist
Requirements 1
Resp. Initials
Due Date
The assembly equipment sources have been selected.

Task Not Complete
The assembly equipment design has been kicked off.

Task Not Complete
The equipment design provides for quick change.

Task Not Complete
The equipment design can accommodate fluctuations in volume.

Task Not Complete
Process safety was a consideration in the equipment design.

Task Not Complete
The equipment design includes provisions for mistake proofing.

Task Not Complete
The new equipment was designed and will be built to corporate engineering standards, using standard components.
Task Not Complete 8
The assembly equipment build has been kicked off.

Task Not Complete
A timeline with sufficient equipment detail has been submitted to the customer.
Task Not Complete
10
A list has been prepared identifying all new equipment specific to the project.
Task Not Complete
11
The supplier and equipment contractor have a written acceptance criteria for new equipment. Certified checking fixtures will be available at the assembly equipment source for part run offs.
Task Not Complete
12
Preliminary capability study will be conducted at the equipment manufacturer.

Task Not Complete
14
The feasibility and accuracy of new test equipment has been established.
Task Not Complete
15
A preventive maintenance plan has been started for equipment, including daily, weekly, monthly and annual inspections.
A spare parts list has been identified.

Task Not Complete
17
The receipt of Equipment includes a set(s) of initial spare parts.

Task Not Complete
18
The setup instructions for new equipment are complete and understandable.
Task Not Complete
19
The process characteristics that affect key quality characteristics have been identified.
Task Not Complete
20
Capability or 100% mistake proofing of the key quality characteristics was used in determining acceptance criteria. The manufacturing equipment has sufficient capacity to handle forecasted production and service volumes. In-house testing & measurement capacity is sufficient to provide adequate support for PPAP and problem solving.
Task Not Complete
21
Task Not Complete
22
0% 100%
Supplier Inspection Instructions
Gauge Plan
Gauge design approval
Gauge Checklist
Requirements 1
Resp. Initials
Due Date
The gauge sources have been selected.

Task Not Complete
The gauge designs have been kicked off.

Task Not Complete
The NTG Gauge Manual was used to develop specifications for the gage design. If not, list exceptions.
Task Not Complete 4
Key quality characteristics have been incorporated into the gauge design.
Task Not Complete
Process safety has been considered in the design of the gages.

Task Not Complete
The Gage Plan has been completed and signed off by the SDE.
Task Not Complete
The gage builds have been kicked off.

Task Not Complete
A timeline with sufficient gage detail has been submitted to the customer.
Task Not Complete
The gage (s) will be complete and certified in time for the first off-tool parts.
Task Not Complete
10
The gage (s) will be complete and certified in time for the assembly equipment buy-off.
Task Not Complete
11
A GR&R has been planned at the Gage builder using prototype or similar parts.
Task Not Complete
12
The type of gage certification required has been agreed upon with the SDE (3rd Party, gage supplier/part supplier, customer certification). The AIAG Measurement System Analysis GR&R method will be used to determine gage error.
Task Not Complete
13
The maximum allowable GR&R error (% of tolerance) is per AIAG Guidelines.

Task Not Complete
15
Work instructions for gage use will be written and available for the Part PPAP review.
Task Not Complete
16
Job training includes instruction on proper use and care of gages.

Task Not Complete
17
Grain / Paint / Chrome Standards are at location and verified to proper level (Color code and spray date).
All gages are correlated. The parts are able to be layed out with the fixture or correlation studies between the check gages and the CMM holding fixture will be completed and necessary corrections made.
0% 106%
Control Plan Checklist

Requirements 1
Resp. Initials
Due Date
All Significant Product Characteristics (SPC's) and Special Process Characteristics are included in the control plan. SC's are noted on the control plan with a Diamond <D>. All Critical Characteristics realated to safety, FDA regulations, are identified per GMP. Special Characteristics symbols used as requirments. Each line f the control plan has an asspciatied reation plan to aid in containment, process correction and process re-validation. Annual re-validation requirements have been agreed with are included on the control plan. Features that are mistake proofed are easily identified in control plan or the supplier has completed the Mistake Proofing Matrix. A sensor / fixture verification audit is performed on a regular basis to verify that all mistake proofing details are working properly.
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete 7
All gauges and test equipment, as required by the control plan, are available.
Task Not Complete
A review of measurement methods between the supplier and customer has taken place to assure compatibility.
Task Not Complete 9
Lot Traceability is verifiable.

0% 100%
Control plan
Pre Launch Control Plan Checklist

Requirements 1
Resp. Initials
Due Date
All characteristics listed in the pre-launch control plan are being checked 100%.
The inspection methods for each characteristic are listed and approved by the SDE.
Task Not Complete
The format for reporting the measurement/inspection results for trial parts have been reviewed with and agreed to by the SDE. All known customer concerns have been identified to facilitate the selection of key quality characteristics and special process characteristics. All special characteristics (SC's) and special process characteristics are included in the prelaunch control plan. SC's are noted on the pre-launch control plan with a <D>. The pre-launch control plan addresses all incoming (material/components) through processing and assembly, including packaging and shipping.
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Engineering performance testing requirements are identified on the pre-launch control plan.
Task Not Complete
All gauges and test equipment, as required by the pre-launch control plan, are available.
Task Not Complete
All Critical Characteristics realated to safety, FMVSS regulations, are identified per AIAG Special Characteristics sybols per end used requirments. Supporting documantation to safety items will be submitted per shipment.
Task Not Complete
0% 100%
Pre-Launch Control Plan
Measurment report for sample / trial runs
Product / Process Quality Checklist

Requirements 1
Resp. Initials
Due Date
The supplier has identified who will be the Quality Engineer with the customer.
Task Not Complete
The supplier has identified who will be the Quality Engineer with its suppliers
Task Not Complete
A Process/APQP Audit has been performed by Strata (Sections 1, 3, 4, 6 & 21). The manufacturing location has a quality certification. By Which Standard? Last certification date? Next Certification date? List the dates for Certification to EN AS 9100 & ISO 14001 in comments box (if applicable). Is there a First off/Last off (FO/LO) procedure to insure part quality shift to shift.
Task Not Complete Task Not Complete
Task Not Complete 5
Sufficient personnel are available to cover all layout & testing requirements.
Task Not Complete
Sufficient personnel are available to cover all problem solving analysis.

Task Not Complete
Each operation is provided with machine or process instructions that are keyed to the process flow chart & control plan.
Task Not Complete 9
Standard operator instructions are available at each operation.

Task Not Complete
10
Visual aids (pictures or diagrams) are included in the Standard operator instructions. Operators and team leaders were involved in developing standard operator instructions.
Task Not Complete
11
Detailed Layout/Inspection instructions are available.

Task Not Complete
13
5S or other housekeeping measures are an integral part of the workplace.

Task Not Complete
14
There is a documented training program that includes all employees.

Task Not Complete
15
There is a documented training program that lists who has been trained on particular job functions.
There is a documented training program that provides a training schedule.

Task Not Complete
17
Training has been completed for statistical process control and statistical methods, such as capability studies, trend analysis & pareto charts. Training been completed for some type of disciplined problem solving (8-D, 7-step, etc..)
Task Not Complete
18
Training has been completed for other topics as identified. Please list.
Task Not Complete
20
There is a procedure to implement, maintain and establish reaction plans for abnormal production conditions, such as processes being outside of control chart limits (including molding perimeters).
There is an effective root cause analysis system in place.

Task Not Complete
22
Provisions have been made to place the latest drawings and specifications at a point of accessibility. Drawings, catia files and specifications are controlled so as to prevent access to obsolete or unreleased documentation.
Task Not Complete
23
Forms are available for appropriate personnel to record layout/inspection results.

Task Not Complete
25
Provisions have been made to place inspection gages at the monitored operation.
Task Not Complete
26
Provisions have been made to place gage instructions at the monitored operation.
Provisions have been made to place reference or limit samples at the monitored operation.
Task Not Complete
27
Provisions have been made to place inspection logs at the monitored operation.
Task Not Complete
29
Provisions have been made to certify and routinely calibrate gages and test equipment.
Required measurement system capability studies have been completed.

Task Not Complete
31
Required measurement system capability studies are acceptable.
Product / Process Quality Checklist

32
Layout, inspection equipment and the quality facilities are adequate to provide initial and ongoing layout of all details and components. There is a procedure for controlling incoming products that identifies characteristics to be inspected. There is a procedure for controlling incoming products that identifies frequency of inspection and sample sizes. There is a procedure for controlling incoming products that identifies disposition of nonconforming products. There is a procedure to identify, segregate and control nonconforming products to prevent shipment.
Task Not Complete
Task Not Complete
33
Task Not Complete
34
Task Not Complete
35
Task Not Complete
36
Rework/repair methods are documented and posted at the station.

Task Not Complete
38
There is a procedure to requalify repaired/reworked materials.

Task Not Complete
39
Rework/repair procedures have been approved by the customer.

Task Not Complete
40
There is an appropriate Lot Traceability system from raw material to finished product.
Periodic audits of outgoing products are planned and implemented.

Task Not Complete
42
First in/First out (FIFO) is practiced and insured during all phases of the material handling process (receiving through shipping).
Is there a First off/Last off (FO/LO) procedure to insure part quality shift to shift.
Task Not Complete
44
The Launch Containment Plan (I.e. GP12, etc) has been developed and submitted to the Schefenacker SDE for review. There is a plan to support Launch Containment Process activites (manpower, supplies & equipment). The criteria is developed and understood for exiting the Launch Containment Process.
Task Not Complete
45
Task Not Complete
46
0% 100%
Launch Containment Plan
Floor Plan Checklist

Requirements 1
Resp. Initials
Due Date
The floor plan identifies all the required process and inspection points.
Task Not Complete
Areas for all materials, tools, and equipment at each operation are clearly marked.
Task Not Complete
Sufficient space has been allocated for all equipment including storage of dies, gages, dunnage, visual aids, ingredients, sub-assemblies and any sub components.
Task Not Complete 4
Process and inspection areas are of adequate size and easily accessed.
Task Not Complete
Light levels in the Process and inspection areas are acceptable.

Task Not Complete
Inspection areas contain necessary equipment and files?

Task Not Complete
Part and material Staging Area's are adequate.

Task Not Complete
Non-conforming material areas are of adequate size, can be secured, and are clearly marked. Inspection points are logically located to prevent shipment of nonconforming products. Controls have been established to eliminate the potential for an operation, including outside processing, to contaminate or mix similar products.
Task Not Complete
Task Not Complete
10
Material is protected from overhead or air handling systems contamination.

Task Not Complete
12
The cell layout is complete and has been approved by a cross-functional team.
0% 100%
Purchasing / Supplier Checklist

Requirements 1
All sub-suppliers and contractors have been selected for material, components, tooling, gauges, and equipment. Material & Component sub-suppliers are on schedule with tooling & equipment to support the project timeline and milestones. Purchase orders have been issued for all material & components to support the start of production trials. Purchase orders to lower tier suppliers contain terms & conditions relating to quality standards for the sub-suppliers (Cpk, material certification, PPAP level/requirements, standards, PPM, etc.). Sub-suppliers have submitted current timelines to the suppliers purchasing and project management. Sub-suppliers have received forecast and ramp-up schedules to support all production trials, system fill, SOP and peak volume demands.. Production level Material has been defined and is it the same material that will be used from the start of the production trials. The engineering level of the material & components for the start of the production trials match the current released engineering level. All Material & Component PPAP's with the sub-suppliers are complete and have received full PPAP approval.
Resp. Initials
Due Date
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
All packaging (production) has been approved, staged and ready for launch
0% 100%
Packaging & Material Control Checklist

Requirements
Resp. Initials
Due Date
Packaging data forms have been submitted to Strata.

Task Not Complete
The Packaging design has been approved by the Strata team.

Task Not Complete
The packaging is sufficient to prevent damage to all parts, particularly those parts with plating, painting, critical appearance criteria.
Task Not Complete
The quantity of containers is sufficient to support system fill and SOP.

Task Not Complete
Alternate containers or packaging has been investigated in case of unforseen circumstances. The details of part transportation and delivery have been agreed to with the suppliers and customers
Task Not Complete
Task Not Complete
The supplier has made all the appropriate contacts to enable a smooth communication flow and conduct necessary business (engineering change control, inventory control, packaging & logistics, service & parts, purchasing, quality, engineering liaison, accou
Task Not Complete
The suppliers has received forecast and ramp-up schedules to support all production trials, system fill, SOP and peak volume demands..
Task Not Complete
The Supplier has completed the Self Assessment.
0% 100%
PPAP Part Checklist

Requirements 1
Samples parts for the Production Validation (PV) have been secured and PV testing is proceeding to the agreed schedule. A preliminary Run@Rate has been performed and the production rate is acceptable to meet the launch curve at the necessary quality level. The tier 1 supplier has reviewed the production capacity at all lower tier suppliers. The production rates are sufficient to meet the launch curve at the necessary quality level.
Resp. Initials
Due Date
Task Not Complete
Task Not Complete
Task Not Complete 4
The Gage Plan has been completed and signed off by the SDE giving approval to use the gage in series production.
Inspections Methods are complete and to the latest engineering level for each shipping unit. Copies are included in the PPAP submission. The Launch Containment Plan has been agreed by Strata and has been implemented at the supplier. Pre-grain samples have been submitted to Strata. The supplier has received authorization to grain the tooling.
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete 8
Grained samples have been submitted to Strata.

Task Not Complete
Color and gloss samples have been submitted to Strata, if required.

Task Not Complete
10
Process numbers match between Process Flow Diagram, Process FMEA, and Control Plan.
0% 100%
Preliminary Run at Rate
PPAP Element Checklist

Requirements 1
Resp. Initials
Due Date
The PPAP sample parts have been produced to the latest engineering change level and have been shipped to the customer for PPAP approval with necessary data.
Task Not Complete 2
All material test results are complete, acceptable and referenced in the PPAP submission.
Task Not Complete
All components parts and materials have received full PPAP approval from suppliers. All supplier's PPAP's (tier 2) are referenced within the PPAP submission. A run @ rate has been performed and documented by the NTG SDE. The production rate is sufficient to sustain full series production at published volumes. The part is being produced at the current engineering release level with no open deviations.
Task Not Complete
Task Not Complete
Task Not Complete 6
The Process Flow, PFMEA and Control Plan have been updated to reflect the current manufacturing & quality processes.
The Production Validation (PV) Testing is complete and parts from the series tooling & processes meet all known Specifications (Drawing, OEM Specifications, SAE, ASTM, etc..). A summary of the PV test plan and report is included in the PPAP documentation The Launch Containment Plan has been effective in capturing all defective material at the supplier location. All PPAP documentation is complete (utilize AIAG guidelines) and the package has been reviewed internally prior to submission to the Customer.
Task Not Complete
Task Not Complete
Task Not Complete
Task Not Complete
(1) Part Submission Warrant

10
"Part number" is NTG Part Number. "Engineering Drawing Change Level" and "Date" is NTG Drawing Level and Date. "Shown on Drawing" is NTG Drawing. "Weight (kg)" is to four (4) places expressed in kilograms. NTG Supplier Code is
11
(2) Engineering Change Documents (3) Customer Engineering Approval
Task Not Complete
All, if any, applicable NTG Change Control Notices (CCN's) included. If none insert sheet saying not applicable.
Task Not Complete
All, if any, applicable NTG Tool Life Deviations (TLD's) included. If none insert sheet saying not applicable.
Task Not Complete
(4) Dimensional Results

The part layouts are acceptable. All dimensions are within tolerance. If no dimensional layout necessary then insert sheet saying not applicable.
Task Not Complete
A six (6) piece per cality (minimum) part layout is complete. The layout includes 100% of all dimensions (as default) or all of those dimensions agreed with the SDE. All print notes are referenced on layout.
Task Not Complete
Dimensional results of the part layout are documented in the format agreed with the SDE. Dimensional results are referenced by balloon number on ballooned print (included in PPAP submission).
Task Not Complete
If necessary, special layout set-ups for dimensions are reviewed and approved by customer before PPAP submission.
Task Not Complete
(5) Initial Process Study

5
All significant and critical characteristics have initial process studies. Sample size is per AIAG Guidelines. If drawing does not contain critical dimension(s) then characterstic to measure shouwl be agreed upon with the Enginee All required capability studies have been performed and meet requirements of 1.67 Ppk/Cpk.
Task Not Complete
(6) Measurement System Analysis Studies
Task Not Complete
A GR&R is performed for every gage used on the control plan, process study.
Task Not Complete
Gage R&R's have been completed for all checking fixtures and test equipment, associated with the shipping unit, intended for production use. GR&R's are equal to or less than the target as per AIAG Guidelines.
Task Not Complete
(7) Checking Aids

7
All checking fixtures associated with the shipping unit are certified and certification is referenced in the PPAP submission. If none insert sheet saying not applicable.
Task Not Complete
Layouts are included for attribute gaging to verify compliance.

Task Not Complete
(8) Material, Performance Test Results
A summary of the PV test plan and report is included in the PPAP documentation.
PPAP Element Checklist

Task Not Complete 7
Results for Performance Testing are included in PPAP submission.

Task Not Complete
A summary of material tests / specifications is included in the PPAP documentation
Task Not Complete 6
Results for Material Testing / Specifications are included in PPAP submission.

Task Not Complete
Restricted or reportable substances report - appropiate OEM form is included (CS9000, GM3059, WSS-M99P9999-A1 report).
(9) Qualified Laboratory Documentation (10) Design FMEA
Task Not Complete
Documentation is provided showing lab is approved to perform testing (ISO/TS 16949:2002, A2LA, ISO25, etc.).
Task Not Complete
Design FMEA is included in PPAP submission. If not design responsible, insert sheet saying not applicable. If Design FMEA is propietary, insert sheet saying propietary and only for review at supplier location.
Task Not Complete
(11) Process FMEA

7
Process FMEA is included in PPAP submission. If Process FMEA is propietary, insert sheet saying propietary and only for review at supplier location.
Task Not Complete
(12) Process Flow Diagrams
Process Flow Diagrams are included in PPAP submission.
(13) Control Plan

Control Plan is included in PPAP submission.
Task Not Complete
(14) Appearance Approval Report (AAR)
Task Not Complete
The Appearance Approval Report (AAR) has been completed for grain, gloss & color and accepted by SVS and OEM.
(15) Records of Compliance with Customer-Specific Requirements

A copy of TS/QS/ISO registration is included in the PPAP submission.
Task Not Complete
Task Not Complete
(16) Master Samples

2
Master samples have been retained by the suppliers for use in making acceptance and boundary samples. Insert sheet in PPAP submission stating master samples retained at supplier.
(17) Sample Product

6
Task Not Complete
Two (2) samples are included in PPAP submission. Samples are to be marked with program, part number, print revision level, and date of PSW (date supplier signed PSW).
(18) Bulk Material Requirements Checksheet
Task Not Complete
For bulk material suppliers only. Insert sheet saying not applicable if do not need checksheet.
(19) Design Records of Saleable Product

All Design records are included in submission. Ballooned print for dimensional results is included in PPAP submission.
Task Not Complete
0%

100%
Supplier - Special / Pass-Thru Characteristics Form

Optional Form Check All That Apply 'X' PFMEA Severity [use AIAG]
Drawing Zone
Special [S.C]
Special or Pass Through Characteristic
PFMEA RPN
Functional
Impact of Failure
Prevention: Detection: Prevention: Detection: Prevention: Detection: Prevention: Detection: Prevention: Detection: Prevention: Detection: Prevention: Detection: Prevention: Detection: Prevention: Detection: Prevention: Detection:
Date
BW Supplier Dev. Representative
Sign
Supplier Representative:
63423512.xls.xls
Fit
Special - Pass Thru List 48/51
Rev. Date 7/21/06
racteristics Form
Cpk [C] or Error Proof [E]
Current PFMEA Process Controls
Target Date
63423512.xls.xls
Status R/Y/G
Special - Pass Thru List 49/51
Rev. Date 7/21/06
DEFINITIONS
controlled document in accordance to FDA & National Regulations
Risk High Moderate None
Color Red Yellow Green
Risk/Status Assessment Definition Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work plan does not achieve program targets. Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieve program targets, and has been approved by the appropriate Management Team Target dates and deliverables are on track and meeting objectives.
Form APQP Open Issues Meeting Log Feasibility Pass Through
Form Requirements Process Required/Optionoal R R O R O
Form Required/Optiona R O O O O
63423512.xls.XLS
definitions 50/51
Rev. Date: 7/21/06
DEFINITIONS
ument in accordance to FDA & National Regulations
Risk/Status Assessment Definition re at risk. A recovery work plan is not available and/or implemented, or the work plan does not
re at risk, but a resourced recovery work plan has been developed to achieve proved by the appropriate Management Team on track and meeting objectives.
Form Requirements Form Required/Optional R O O O O
63423512.xls.XLS
definitions 51/51
Rev. Date: 7/21/06

APQP Project Management Checklist

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APQP Project Management Checklist

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APQP Product Development System (PDS) - Project : Project Management position

Concept Project Approval Prototype Pilot SoP

Handover Period SoP +/- 90 days

Model and Drawing Design Review

Manufacturing Facility Design Approval

Tooling Design Freeze

Handover Period SoP +/- 90 days

Production Support Production Controlling MR5 PS5

ing PDS processes

Advanced Product Quality Planning ( APQP) Checklist

Mr. Robbie Howarth

Build Level Prototype

Project Due Date

Internal Completion Date Completion Date Champion Name

Document Revision Date & Rev. Comments / Action Plan

Phase 0.0 Project Initiation

Phase 1.0 Plan and Define Project

Phase 2.0 Product Design & Development

Phase 3.0 Process Design and Development

Phase 4.0 Product and Process Validation

Phase 5.0 Feedback, Assessment and Corrective Actions

Ops Team UM/FWW

APQPSTAT (UK Version) 5/51

Rev. Date: 7/21/06

Advanced Product Quality Planning

0.1 0.2 0.3 0.4 0.5

Phase 1.0 Plan & Define Project

1.1 1.2 1.3 1.4 1.5 1.6 1.7

Phase 2.0 Product Design & Development

Phase 2.0 Product Design & Development

B Behind schedule with no catch up plan

Issued By: Issued Date: Issue No.:

Latest Date : 07/21/2011

Issued By: Issued Date: Issue No.:

Latest Date : 07/21/2011

Issued By: Issued Date: Issue No.:

Latest Date : 07/21/2011

Advanced Product Quality Planning ( APQP) Checklist

Formularnummer: Anlage zu EW 017 10/27/2008 6953.49.00 3 Hausach

Hr. Dr.Koerner Hr. Roser Hr. Schmid

Projektleiter Projektmanagement Industrialisierung

ekkehard.koerner@neumayer-tekfor.com tobias.roser@neumayer-tekfor.com erwin.schmid@neumayer-tekfor.com

Build Level Prototype

Internes Soll Datum

Document Revision Date & Rev.

Phase 0.0 Project Initiation

Phase 1.0 Plan and Define Project

Phase 2.0 Plan and Define Project

Phase 3.0 Process Design and Development

Phase 4.0 Product and Process Validation

Phase 5.0 Feedback, Assessment and Corrective Actions

Ops Team UM/FWW

APQPSTAT (German Version) 10/51

Rev. Date: 7/21/06

Advanced Product Quality Planning ( APQP) Checklist

Formularnummer: Anlage zu EW 017 10/27/2008 6953.49.00 3 Hausach

Hr. Dr.Koerner Hr. Roser Hr. Schmid

Projektleiter Projektmanagement Industrialisierung

ekkehard.koerner@neumayer-tekfor.com tobias.roser@neumayer-tekfor.com erwin.schmid@neumayer-tekfor.com

Build Level Prototype

Internes Soll Datum

Document Revision Date & Rev.

Phase 0.0 Project Initiation