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ASIAN AUTOMOTIVE STEELS

12.08.10
Customer request
Development

CONTRACT
REVIEW

Marketing
Development

Customer RFQ
product documents
delivery requirements (customer statement)
Customer
Credit Check

Credit Critera failed

Marketing
Credit / Audit Report

Project risk assessment

Vendor information

RFQ vendor

SGM / GM authorization

outsource

Vendor RFQ

Vendor feedback
No go

Request Customer
Specific Requiremen

Preliminary RFQ
analysis

Quotation
reject,
Counter
proposal
Development
Manufacturing
Purchasing
Engineering

CSR

Statement of Deliverables (internal RFQ form)


Preliminary process flow
APQP checklist
Draft APQP organization chart

Vendor
preliminary
proposals

Technical
feasibility

Reject

APQP team counter


proposal

Accept:
Team Feasibility Commitment
m/c cycle time
Costing assumption

Preliminary planning

Development

Project Development Costing


Manufacturing costing
Preliminary project schedule
Project FS

Accounts

FS documents

Document compilation
Quotation analysis, Proposal
Quotation letter

Marketing
Change
request

Management
support

Marketing

GM, SGM Endorsement

Inform customer

Close project order

MD/COO
approval

Change
request
Marketing

Signed quotation
Project Authorization
RFQ rejection
memo

Document submission

Marketing

Customer quotation forms, packaging


Delivery/Acceptance document
Project close

No
reject letter
from customer

Customer
accept?

Record in quotation file

LOI / LOA

Quotation file

Product Design &


Development

File: Procedure APQP.vsd

Page 1

Marketing

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

CONTRACT AMMENDMENT
& VA/VE

Engineering change
proposal
Customer ECN/ change
product documents
delivery requirements
Technical concept
study
Technical feasibility evidence
Preliminary
Go/No Go

Counter
Proposal

GM endorsement, customer endorsement


Commercial Feasibility not OK
Team feasibility commitment not OK

Commercial feasibility
study
Commercial Feasibility study OK
Team Feasibility commitment OK
Start decision
proceed

outsource

Not feasible

RFQ approved vendor


Vendor RFQ
Vendor feedback
Vendor proposals

Preliminary planning

Preliminary process analysis


Project Development Costing
Manufacturing costing
Preliminary project schedule
Project feasibility study

Change
request

Document compilation

Analysis documents

Preliminary quotation

Quotation Letter

Counter proposal

Change
request

GM
endorsement

Counter propose

Forward to MD
MD/SGM
endorsement

Counter proposal

Signed quotation
Project Authorization
Trasmit to customer

Confirmation of receipt
Customer
accept?
LOI / LOA/ PPA ammendment
product
development
File: Procedure APQP.vsd

Page 2

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

PRODUCT DESIGN & VALIDATION


LOI /
Customer authorization

Yes, resourcing /
localization

Design
document
avail?

No, new design


product validation req

Sample
available?

no

Customer liaison

Correspondents, minutes
Customer product
specs, stds avail?

Customer needs
analysis

yes
No / incomplete

Customer
requirements
Reverse engineering
Yes; drawing, spec, testing std

revise

Quality Requirement
analysis

Product specification
proposal

Bill of materials
incoming material requrement
process requirements
Specification list

Product design /
verification
manual calculations
FEA output
product design drawing
proto pfmea, control plan

testing list
approval
Customer-approved
PIS, testing list
Product validation
Test planning/design
Testing
Test eqpt, method
documentation
requirement
requirement

Test document
preparation

product
std

Prototype part,
interfaces
purchase / mfg
Sample
purchase
documents

Testing arrangement
equipment prep

Product analysis
QFD / DFMEA

QFD, DFMEA
form

(Specifications
not compatible,
emerging
Requirements)
Product
Change
Request

sample parts
Fitting, performance
analysis

Fitting trial checksheet


Testing checksheets

Status reports
inspection
checksheet
template

Prototype testing,
analysis

Sample
testing
results

Spec
review /
DQCM

PRODUCT SPECIFICATIONS
Product drawing (comp & assy)
Testing specification,
Part Inspection Standard
Packaging specification
Product
document
release

File: Procedure APQP.vsd

Page 3

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

PRODUCT DOCUMENT RELEASE


Product specification
product document
draft / update/ correction
draft drawing

document log update

update drawing log


change request

customer
EC approval
req?

yes

EC Request
no

(customer
preliminary document
review)
approve for final submission

final document preparation


final document

document
check - approve

signed document

document submission

proof of delivery

contract
ammendment
req?

customer
endorsement

yes

customer-approved document

Document Control

Contract Ammendment
no

Process development
planning

File: Procedure APQP.vsd

Page 4

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

PROCESS DEVELOPMENT PLANNING


LOI / LOA +
Product Specifications
Process requirement
analysis
Process flow diagram
PFMEA
Special Process characteristics

Sourcing plan

Production
Process, inspection
planning
Production Control Plan
Pre-launch Control Plan
Factory layout,
manpower plan
Material, component
sourcing

Engineering
Development Analysis

DevelopmentInspection
/ test eqpt spec MSA plan

Development process flow


Process validation plan
Prelaunch control plan
Equipment Specifications
Development project
planning

Testing inst
development/acq
analysis

Test eqpt requirement /


devp plan

Production m/c requistion /eng development plan


Development Project schedule,
resource requirement, cost estimate

Final proposal
preparation / revision
Change
request

Project Proposal
Management
review

change
request

Authorization to proceed
Confirmed project plan

Transmit final proposal


to customer
management approved proposal
Customer
review

Process
Development &
Validation

File: Procedure APQP.vsd

Page 5

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

PROCESS DEVELOPMENT & VALIDATION


Authorization to proceed

PROCESS VALIDATION

ENGINEERING DEVELOPMENT

Inst purchase/ devp /


mod / training

Eqpt purchase/devp/
mod

Vendor selection

A9 checking aids
inspection jig

Purchasing records

Vendor LOI

checksheet
confirmation

Equipment testing /
checksheets

product
characteristic
ng

test
equipment
fail

VENDOR DEVELOPMENT

mc
ng Agreement
not possible

Equip testing checksheet

Part inspection
standard devp
Vendor drawing
Draft PIS

Eqpt
testing

Approved checksheets
Hard tooling
Product
samples

arbitration

Equip / test reports

Change
terms
Vendor
Devp
failed

Vendor inspection agreement


development contract / LOA
approved quality checksheets

Line trials

line operation status OK


improvement areas

Vendor development

line improvement

Vendor progress reports

Product testing

Dimensional inspection
report, AAR, testing report

Product evaluation

improvement
needed

Vendor monitoring

Line trials

Child
part
ng

sample submission

Sample approval

Vendor evaluation sample

Child part testing


preliminary
PFMEA update

Module testing results


Child part
evaluation
Child part approval
pp appointment

satisfactory
RPN

Vendor PP

Vendor pp summary
Approval Record
master parts

MASS
PRODUCTION
PREPARATION

Subsupplier
PQCM
sign-off

Vendor PQCM

signed vendor PSW


minutes PQCM
Vendor LOA,
draft PPA
draft LOA, PPA

contract nego

term agreement

Vendor PPA
File: Procedure APQP.vsd

Page 6

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

MASS PRODUCTION PREPARATION


process development
review prelaunch
control plan
updated prelaunch, production control plan
list equipment, instrument, work instruction, QC checksheets, manpower
list material & child part ordering
prelaunch preparation
meeting
prelaunch checksheet updata

QC checksheet
preparation

prelaunch, production
work instruction
preparation

equipment servicing,
instrument MSA

prelaunch production
planning

prelaunch material
order

preparation
monitoring

not ready

prelaunch checksheet complete

prelaunch briefing
small batch
trial production
product, process data
minor
issues

product
audit
process ok
line production
confirmation trial
product, process data
product
audit

major issues

process ok
Process
Development

line run at rate

Quality Council
Enquiry

Customer PQCM/PCPN Sign-off


PQP Summary & Sign-off
Production part
documentation
compilation
correction
request

File: Procedure APQP.vsd

APQP records

Project Exit Review

PPAP, Pqcm report

minutes

PQCM

Quality document
update

PSW Sign off

project file document update


product quality standard update

Early production
containment

Project APQP doc


QMS update

Page 7

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

KAIZEN / PROCESS IMPROVEMENT

SCHEDULED
PRODUCTION

Improvement
needed?

Operational problem
Production
QC report

no
Quality
problems?

Quality problem

Improvement possible
Problem analysis

Kaizen request for


proposals

Improvement
ideas
Kaizen submission

Additional Testing /
data gathering

Kaizen
Evaluation
Proposal accepted

Test reports,
data analysis
Project planning

Kaizen proposal

Minutes
project schedule

Modification

Tooling / mc redesign,
fabrication

Problem
description

Temp rigging,
work inst

Temporary production
rigging, work inst

Process ref update


m/c maintenance log update
Off-line testing

m/c maintenance log update


Problem
resolved?
Target achieved
Supervised
production

Statistical data
PFMEA updates
process improvement activities update
SPC data update

Acceptable?

improvement
project close

File: Procedure APQP.vsd

Kaizen award
presentation

Page 8

Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

PROJECT GO/NO-GO DECISION

Volume commitment
Material
cost quotation

Dev cost
estimate

Compute costs / pc,


capital investment

Process cost
estimate

Standard costing sheets

Marginal cost meet


customer price?

No
Yes

Management
prerogative

No

Full costing meet


customer price?

Yes
Project Authorization Memo

4TH down & 20


GO FOR IT!

Quotation issue

Inform customer NG

File: Procedure APQP.vsd

Page 9

Prepared: AG