LOP: new OP Deutsch

Logged in edit OP
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Responsible for
this LOP: Carter expired Points: 0017 CW 2508 ● English
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Due
Propose Closed
No. Status Applied at Subject Description Responsible date Further information
d by (CWYY)
(CWYY)

1 open 05/11/07 Jende Phase 1 2.1 Checlist Required Thyen 1708

2 open 18/04/08 Beeler Phase 6 Base Information in place Carter 1808
3 open 18/04/08 Beeler Phase 3 18.4 need document for part buy off to ship from tool shop Meelich 1508
Implement Rust prevention costs a and plan in APQP quote and control
4 open 18/04/08 Beeler Rust Ade 1508
process
5 open 18/04/08 Beeler Phase 1 Packaging Requirements - volume and capacity Thyen 1508
6 open 18/04/08 Beeler Phase 1 2.10 create assembly sheet Thyen 1608
7 open 18/04/08 Beeler Phase 1 5.12 Template needed Prochak 1508
8 open 18/04/08 Beeler Phase 2 8.2 Standardize contact communication list - use list from JC Ade 1608
9 open 18/04/08 Beeler Phase 2 8.5 template needed for CMS entry (BOM, Etc.) Thyen 1708
10 open 18/04/08 Beeler Phase 2 9.5 checklist needed for design review and manufacturability Wiggins 1708
Meelich
11 open 18/04/08 Beeler Phase 2 11.3 form required for check fixture buy-off 1708
Prochak
12.10 Lessons Learned form required - move to phase 1 for quote. Add Carter
12 open 18/04/08 Beeler Phase 2 1708
to mgmnt review and remove this line Team
13 open 18/04/08 Beeler Phase 3 18.6 Packaging sign-off form required Carter 1708
14 closed 18/04/08 Beeler Phase 3 19.2 Preventative Maint. form required Carter 1508 1608 Removed from list. Not required
15 open 18/04/08 Beeler Phase 3 19.3 Weld Maintenance form required to verify plan Carter 1608
Move to phase 0-28 - 4-08-08 Beeler - verify doc.
16 open 18/04/08 Beeler Phase 3 20.10 Die coatings for die standards Carter 1708
requirement
17 closed 18/04/08 Beeler Document Construct executive sign-off sheet Team 1508 1608 Add Quality and Logistics Sign off to Sheet
Deleted 4-8-08 Beeler on Rev. 22 - MB3 in the
18 closed 18/04/08 Beeler Phase 2 Are 12.1, 12.2, 12.3, 12.4, 12.6 required or used? Team 1508 1608
file for reviewe
19 closed 18/04/08 Beeler Phase 0 Break Phase 1 into Phase 0 and Phase 1 Carter 1508 1608 Completed 04-08-08 Beeler
20 closed 18/04/08 Beeler Phase 1 Move EDI to Phase 1 Carter 1508 1608 Comleted 04-04-08 Beeler
End of Life Checklist on U: Drive. needs to be controlled document and Carter
21 closed 18/04/08 Beeler Phase 6 1508 U:\Projects\Benteler\Sta-Bar End of Life 2008
verify all actions are listed Wiggins
22 open 25/04/08 Carter Contingency Proposal to add back up contingencies to specific part JI's Carter 2008
23 open 25/04/08 Carter Packaging Buy-off Instructions Matt Foster 1908

493954227.xls Printdate: 10/07/2020 1 / 26

 LOP:
Additional Information
Nr. Date Comments 149 3
Surname Forename e-mail Phone LM-Number
1508
Ade JC jcade@ssprod.com
Beeler Mark mbeeler@ssprod.com
Burke Sean sburke@ssprod.com
Carter Dana dcarter@ssprod.com
Jende Holger hjende@ssprod.com 864 6993240
Jende Holger hjende@ssprod.com 864 6993240
Lane Charlene clane@ssprod.com
Matt Foster
Meelich Steve smeelich@ssprod.com
Prochak Grace gprochak.com
Team
Thies Steve sthies@ssprod.com
Thyen Jack jthyen@ssprod.com
Wiggins Buck bwiggins@ssprod.com
Version: 2.0
1
14
english
 Contingency 01 2006
2508 Document 02 2007
2 New subject 03 2008
bearbeiten Packaging Buy-
04 2009
bearbeiten Phase 0 05 2010
Phase 1 06 2011
Phase 2 07 2012
Phase 3 08 2013
Phase 6 09 2014
Rust 10 2015
11 2016
12 2017
13 2018
14 2019
15 2020
16 2021
17 2022
18 2023
19 2024
20 2025
21 2026
22 2027
23 2028
24 2029
25 2030
26 2031
27 2032
28 2033
29 2034
30 2035
31 2036
32 2037
33 2038
34 2039
35 2040
36 2041
37 2042
38 2043
39 2044
40 2045
41 2046
42 2047
43 2048
44 2049
45 2050
46 2051
47 2052
48 2053
49 2054
50 2055
51 2056
52 2057
53 2058
 PHASE GATE Phase Gate Start Date Current Revision
APQP Program Status dd/mm/yr dd/mm/yr

Customer Program Manager

Project
Core Team
SOP

Activity Phase Gate Activity Due Close Primary Status

Evidence Comments
Number Advanced Product Quality Date Date Responsibility R/Y/G

Phase Gate # 0 Project Quote Validation

0 Assign program manager Notification of Assignment Executives
1 Review Quotation and Team Feasibility F02.039/F02.027 Quote Management
2 Purchase Order or LOI received from customer Customer PO Business Development
3 Validation of Purchase order (PO) or letter of intent (LOI) from customer Customer PO Business Development
3.1 Validate customer specific requirements (Specs and standards- supplier quailty manual review) Meeting Minutes Program Management
3.2 Validate product / process / technology requirements / packaging / poka yoke F02.027 Program Management
3.3 Validate manufacturing feasibility / capability / capacity / poka yoke F02.027 Program Management
3.4 Validate bill of material BOM Program Management
3.5 Validate tooling process sheet F02.044 Program Management
3.6 Validate customer credit worthiness Credit Verification Program Management
3.7 Validate suppliers quotations. F 02.025 Program Management
3.8 Submit commercial changes to customer. Business Development
4.0 Conduct management review of phase gate # 0 (Update Lessons Learned) Phase gate 0 - LOP Program Management
4.1 Exit Approval of Phase Gate "0" based on Project LOP. Contained in Quote Sign off F02.010 Executives

Phase Gate # 1 Planning and Program Definition (Program Initiation & Approval)
5 Program Preparation
5.1 Create Project LOP LOP Program Management
5.2 Create / Approve project cost control (PCC - cost tracking) F09.144 Program Management
5.3 Establish program team members, roles, and organizational chart Contact list Program Management
5.4 Define training required for team, new technologies, processes, etc… Training Matrix Program Management
5.5 Define communication plan (Internal core team / Executive Reviews) Meeting schedules Program Management
5.6 Hold kick off meeting with customer Meeting minutes Program Management
5.7 Review project PPAP requirements with team Customer Supplier Manual Quality
5.8 Set-Up and Create Electronic Program Books (E-Books) Network Program Management
5.9 Develop program timeline Timeline Program Management
5.10 Review design outputs ts to assure Process Design inputs & outputs Input/Output Matirx Engineering
5.11 Hold kick off meeting with supplier (s) Meeting Minutes Purchasing
5.12 Develop contingency plan (back-up equipment) Open Engineering
5.13 Review costs (actual vs. budget) Finance Report Finance
6 Conduct management review of phase gate # 1 (Update Lessons Learned) Phase Gate 1 - LOP Program Management
7 Exit Approval of Phase Gate #1, based on Project LOP- Signature of Executive Mgmnt. F02.010 Executives

Phase Gate # 2 Product & Process Planning (Development Phase)

8 Updates & Release
8.1 Update program timeline Program Time Line Program Management
8.2 Define Reporting content & layout with customer and supplier Communication Report Program Management
8.3 Release engineering drawing & reconfirm bill of material (BOM) BOM Engineering
8.4 Release supplier purchase order Supplier PO Purchasing
8.5 Begin entry of Production Methods (BOM and Routing) into CMS BOM/CMS Engineering
8.6 Maintain Project LOP LOP Program Management
9 Product & Process Planning
9.1 Determine tooling requirements F02.044 Engineering
9.2 Develop Material Card F0.3001 Engineering

Revision: 29
Form No: F02.011 - ENG-APQP Checklist Issue Date:17 June 2008
Page: 8 of 26
 PHASE GATE Phase Gate Start Date Current Revision
APQP Program Status dd/mm/yr dd/mm/yr

Customer Program Manager

Project
Core Team
SOP

Activity Phase Gate Activity Due Close Primary Status

Evidence Comments
Number Advanced Product Quality Date Date Responsibility R/Y/G
9.3 Determine weld equipment requirements F02.044 Engineering
9.4 Determine facility layout requirements Preliminary Layout Engineering
9.5 Conduct design review for manufacturability and assembly F02.041 Engineering
9.6 Conduct tooling, equipment and layout safety assessments SPG-36-01 & Forms Human Resources
9.7 Confirm logistic concept with customer, internal and external supplier Logistics Concept Program Management
9.8 Confirm Packaging concepts with customer, internal and external suppliers Packaging Concepts Program Management
9.9 Confirm press assignment Engineering
9.10 Establish EDI and shipping label requirements with Customer EDI/Label Requirements Program Management
10 Quality
10.1 Determine inspection fixture requirements (for Datums, and KC's as flowed by the Customers) Customer Drawings Quality
10.2 Define fixture clamping and alignment concept with customer Customer Drawing Quality
10.3 Determine test equipment requirements Customer Test Reqmnts Quality
10.4 Create Failure Mode & Effectiveness Analysis (FMEA), including Poka-Yoke considerations Review Generic PFMEA Engineering
10.5 Create part inspection plan (PIP) F09.124-A,B & C Quality
10.6 Create control plan (CP) Review Generic Cont Plan Quality
10.7 Create weld, sealer, and cross-sectioning destruct PIP DE-JI-01, 02, 03 Quality
10.8 Develop appearance criteria (if applicable) Per Customer Reqmnts Quality
11 Buy Off
11.1 Conduct die design buy off F02.041 Engineering
11.2 Conduct assembly equipment design buy off F02.034 Engineering
11.3 Conduct checking fixture design buy off F09.014 Quality
12 Prototypes (if applicable)
12.1 Complete prototype checklist F02.028 Engineering
12.2 Kick off Due Builds Purchasing
12.3 Verify die builds at prototype tool shop Dies Engineering
12.4 Build prototype parts Prototype Parts Engineering
12.5 Review prototype parts Against Drawings/Math Data Engineering
12.6 Review Prototype parts with Customer for feedback Review Minutes and Actions Quality
13 Review costs (actual vs. budget) Finance
14 Conduct management review of phase gate # 2 (Update Lessons Learned) Phase Gate 2 - LOP Program Management
15 Exit Approval of Phase Gate #2, based on Project LOP- Signature of Executive Mgmnt. F02.010 Executives

Revision: 29
Form No: F02.011 - ENG-APQP Checklist Issue Date:17 June 2008
Page: 9 of 26
 PHASE GATE Phase Gate Start Date Current Revision
APQP Program Status dd/mm/yr dd/mm/yr

Customer Program Manager

Project
Core Team
SOP

Activity Phase Gate Activity Due Close Primary Status

Evidence Comments
Number Advanced Product Quality Date Date Responsibility R/Y/G

Phase Gate # 3 Die / Assembly Equipment Manufacturing & Pre Launch Preparation
16 Updates & Reviews
16.1 Update program timeline (incl. HLC plan) Program Time Line Program Management
16.2 Maintain Project LOP Project LOP Program Management
17 Quality
17.1 Conduct measurement system analysis (MSA) - gage R&R F09.023 Quality
17.2 Defiine Appearance Approval Requirements Customer Requirements Quality
17.3 Define statistical tools to be utilized (if applicable) Capability Studies/MSA's Quality
17.4 Update FMEA / CP / PIP Updated Docs Engineering/Quality
17.5 Review purchase parts supplier PPAP (production part approval process) requirements SQM Supplier Quality
17.6 Review tool/equip supplier buy off requirements Supplier PPAP Quality Add Tooling/Equipment Checksheets
18 Buy offs
18.1 Conduct die buy off (tool shop) F02.023 A & B & F02047 Engineering
18.2 Conduct Appearance Approval Create Boundry Sample Quality
18.3 Conduct assembly equipment buy off (tool shop) ENG-PR-05, S02018, F02.034 Engineering
18.4 Conduct checking fixture buy off ( tool/gage shop) F09.014, QA-PR-08 & 05 Quality
18.5 Conduct part buy off (Tool Shop) Part Submission Warrant (PSW) Quality
18.6 Process Verification for Thinning F09.089 Engineering
18.7 Conduct packaging / rack buy off--- Approved Specification/Drwgs Engineering
19 Pre Launch Preparation
19.1 Verify preventive maintenance plan - tool & die F07.100-107, EN-PR-02/Tool & Die DB Engineering
19.2 Verify preventive maintenance plan - weld assembly MFG-PR-03/Maintenace Data base Engineering
19.3 Confirm indirect labor Operations
19.4 Define work cell layout / ergonomic review Floor Plans Engineering
19.5 Conduct safety / environmental / ergonomic buy off Floor Plans Human Resources
19.6 Create process instructions (machine set up / job instruction) F02.051 / F02.052 Engineering
19.7 Define training plan QA-PR-13/Training Matrix Project Management
20 Pre launch requirements
20.1 Production Material available (raw steel) Inventory Verification Purchasing
20.2 Purchased parts available (weld nuts, studs, etc…) Inventory Verification Purchasing
20.3 Material certifications available Material Certifications Purchasing
20.4 Material storage plan complete Plant Layout Logisitics
20.5 Packaging storage plan complete Packaging Storage Plan Logisitics
20.6 WIP packaging plan complete WIP Storage Plan Operations
20.7 Finished goods packaging plan complete FG Packaging Plan Logisitics
20.8 Provide check fixture storage plan Plant Layout Operations
20.9 Provide die storage plan Plant Layout Operations
21 Logistic
21.1 Implement part into scheduling system (production scheduling) Schedule Validation Production Planning
21.2 Validate EDI communication with customer EDI Validation Production Planning
22 Review costs (actual vs. budget) Program Management
23 Conduct management review of phase gate # 3 (Update Lessons Learned) Phase Gate 3 - LOP Program Management
24 Exit Approval of phase gate #3, based on Project LOP. Signature of Executive Mgmnt. F02.010 Executives

Revision: 29
Form No: F02.011 - ENG-APQP Checklist Issue Date:17 June 2008
Page: 10 of 26
 PHASE GATE Phase Gate Start Date Current Revision
APQP Program Status dd/mm/yr dd/mm/yr

Customer Program Manager

Project
Core Team
SOP

Activity Phase Gate Activity Due Close Primary Status

Evidence Comments
Number Advanced Product Quality Date Date Responsibility R/Y/G

Phase Gate # 4 Product and Process Validation (Pre Launch / HLC)

25 Updates & Reviews
25.1 Update program timeline (incl. HLC plan) Program Timeline Program Management
25.2 Maintain Project LOP Project LOP Program Management
25.3 Update Production Methods (BOM and Routing) in CMS including Net Weight Verification CMS CMS Contoller
25.4 Confirm Production Methods (BOM and Routing) and EDI/Labels in CMS BOM/CMS Production Control
25.5 Verify Release Accounting (Customer Demand and Pricing) in CMS CMS Program Management
25.6 Update contingency plan (back up press, etc…) Open Operations Ref. 5.12
26 Quality
26.1 Check fixture audit complete F09.014 Quality
26.2 Perform stamping "full part" layout incl. Pp, Ppk study QA-PR-12/Capability Data Quality
26.3 Perform assembly "full part" layout incl. Pp, Ppk study QA-PR-12/Capability Data Quality
26.4 Conduct weld performance test (destructive) DE-JI-01, & 02/PIP Quality
26.5 Record quality concerns in CCN database CCN Quality
26.6 Create master sample panel Master Sample Quality
26.7 Create visual aid panel (boundary sample) Boundry Samples Quality
26.8 Update FMEA / CP / PIP Updated Documents Engineering/Quality
26.9 Conduct project team review - corrective & preventive action log Program LOP Engineering/Quality
26.10 Complete all PPAP conditional requirements - re submit if necessary PPAP Book Engineering/Quality
26.11 Submit PPAP (production part approval process) to customer PPAP Book Engineering/Quality
27 Training
27.1 Perform stamping check fixture training F04.003 Training
27.2 Perform assembly check fixture training F04.003 Training
27.3 Conduct operator training F04003/QA-PR-13 Training
28 High volume production trial (HVPT)
28.1 Safety / environmental / ergonomic buy off SPG-40-01 Human Resources
28.2 Assembly shop tooling and equipment buy off (HLC) ENG-PR-05, S02018, F02.034 Engineering
28.3 Press shop tooling and equipment buy off (HLC) ENG-PR-05, S02019 & 29, F02.023a & b Engineering
28.4 Conduct high volumn production run (HVPT) ENG-PR-03/F02.042 Operations
28.5 Correct any deficiencies from HVPT F02.043 Project Team
29 Invoice customer for tools , fixtures and gages Invoice Finance
30 Review costs (actual vs. budget) Cost Analysis Finance
31 Team sign off on project - turn project over to production F02.010 Program Management
32 Conduct management review of phase gate # 4 (Update Lessons Learned) Phase Gate 4 - LOP Program Management
33 Exit Approval of phase gate #4, based on Project LOP- Signature of Executive Mgmnt. F02.010 Executives

Phase Gate # 5 Feedback, Assessment and Corrective Action (Production)

34 Verify equipment and tooling readiness HVPT Signoff Operations
35 Release production schedule (Move forward) Production Schedule Logistics
36 Release production raw material orders (Move forward) Raw Material Orders Purchasing
37 Release purchased part orders (Move Forward) Purchase Orders Purchasing
38 Confirm Production Methods (BOM and Routing) and EDI/Labels in CMS CMS Logistics
39 Start Production Project Timeline Operations
40 Close Project LOP Project LOP Program Management
41 Conduct team lessons learned Lessons Learned Program Management
42 Conduct management review of phase gate # 5 ( Update Lessons Learned) Phase Gate 5 - LOP Program Management

Revision: 29
Form No: F02.011 - ENG-APQP Checklist Issue Date:17 June 2008
Page: 11 of 26
 PHASE GATE Phase Gate Start Date Current Revision
APQP Program Status dd/mm/yr dd/mm/yr

Customer Program Manager

Project
Core Team
SOP

Activity Phase Gate Activity Due Close Primary Status

Evidence Comments
Number Advanced Product Quality Date Date Responsibility R/Y/G
43 Exit Approval of phase gate #5, based on Project LOP- Signature of Executive Mgmnt. F02.010 Executives

Phase Gate # 6, Program Exit Planning

44 Customer contract review for service requirements ENG-PR-11 Quote Management
45 Receive Customer program exit timing plan. Customer Exit Plan Business Development
46 Supplier exit plan (verify service responsibilities and communication) Supplier Exit Plan Purchasing
47 Material and part obsolescence plan Obsolesence Plan Logistics
48 Ramp down schedule planning Logistics Plan Logistics
49 Packaging and logistics review Logistics Plan Logistics
50 Tool and gage storage (service requirements) Storage and Service Plan Quality
51 PIP and JI review for changes to run service PIP/JI Review Quality
52 Part storage (service requirements) Storage Plan Logistics
53 Conduct team lessons learned Lessons Learned Project Team
54 Conduct management review of phase gate # 6 (Update Lessons Learned) Phase Gate 6 - LOP Program Management
55 Exit Approval of phase gate #6, based on Project LOP - Signature of Executive Mgmnt. F02.010 Executives

Revision: 29
Form No: F02.011 - ENG-APQP Checklist Issue Date:17 June 2008
Page: 12 of 26
Meeeting attendance tacking-
Team meeting- daily 3-4PM
Last First e-mail Phone 3/31/2008 4/1/2008 4/2/2008
Ade JC jcade@ssprod.com X X X
Jende Holger hjende@ssprod.com 864 6993240 X X O
Meelich Steve smeelich@ssprod.com X X X
Prochak Grace gprochak@ssprod.com
Thies Steve sthies@ssprod.com X
Wiggins Buck bwiggins@ssprod.com X O O
Thyen Jack jthyen@ssprod.com X
Carter Dana dcarter@ssprod.com
Management review meeting
Weekly Mondays @ 3PM

Out of office= O
Vacation = V
Attended= X
39541 39542 4/7/2008 4/8/2008 4/9/2008 4/10/2008 4/11/2008 4/14/2008
X X X X X
X O X X

CANCELED
X X X X X X
X
X
O O X X
O
X
4/15/2008 4/16/2008 4/17/2008 4/18/2008 4/21/2008 4/22/2008 4/23/2008 4/24/2008
X X X X
Member off Site

X X
CANCELED

CANCELED
JC at Dr.
X X X X X

X
X
X
X X X X X
4/25/2008 4/28/2008 4/29/2008 4/30/2008 5/1/2008 5/2/2008 5/5/2008 5/6/2008
X X X X
X X X X

CANCELED

CANCELED
X X X X X

X X
X X
X
X X X X
5/7/2008 5/8/2008 5/9/2008 5/10/2008 5/11/2008 5/12/2008 5/13/2008 5/14/2008 5/15/2008
X X X
X X X
X X X

X
X
X
 Executive Exit Approval for Phase Gat

Name Function

S. Thies CEO Stainless

B. Wiggins EVP BD & SS

B. Bickimer CEO Automotive

S. Gallant CFO

C. Lane VP Quality

C. Lane VP Logistics

J. Thompson Purchasing
 Comments

5
val for Phase Gate # 1 2 3 4 5 6

Date Signature
 Prog. Mgr Lessons Learned
Model Year

Customer Date:
Program
Product
Project #
SSP Plant(s)

Phase Lessons Learned

Things Gone Wrong Recommendation to Preven

Things Gone Right Recommendation to Impleme

earned

SOP DATE
Phase: 1
2
3
4
5
6

ed
mmendation to Prevent on Other Programs

mendation to Implement on Other Programs

 Product End of Life Cycle Checklist
Task # Area Task Completed When? Responsible Comments
1 Bus Dev Understand the reason for the exit Pricing

2 Bus Dev Customer confirmation of end date and qty

3 Bus Dev Notify Organization

4 Prog Manag Define End of of Life Prg Manag

5 Prog Manag Who owns assembly equipment, weld cell, fixtures, ped welder Asset tag management

6 CMS Admin Confirmation in EDI of customer requirements

7 Finance Evaluate Accounts receiveable

8 Purchasing Find out how much run material is ordered

9 Production Planning/Scheduling Cycle count FGD/WIP/RAW

Production Manufacturing
10 Determine effect of manpower
Stamping & Assembly

11 Bus Dev Evaluate PO Agreement and Contract Bank build

12 Bus Dev Confirm service part demand and quote pricing

13 Prog Manag Define customer's exit criteria for the tooling exit PPAP's CMM etc.

14 Finance Book value on equipment

15 Purchasing Identify total amount of material in pipeline

16 Production Planning/Scheduling Determing balance out qty

17 Quality Determine cost associated with PPAP

18 Finance Determine cost of all obsolete inventory Material in process purchased

19 Purchasing Match run material on order to use up of parts

20 Production Planning/Scheduling Determine scheduling changes and effects on press capcity

21 Production Planning/Scheduling Define packages needed for close out and how to return to customer

22 Tool & Die, Weld Tech Scheduling Determine if any spare parts will become obsolete

23 Production Planning/Scheduling Inventory all crib items and costs Spares

24 Prog Manag Define Disposition of tools

25 Bus Dev Negotiate exit costs/bank run/obsolesence

26 Bus Dev Communicate obsolesense cost to customer

27 CMS Admin Deactivate part, delete EDI, close sales and purchase orders

28 Purchasing Close purchase orders

29 Prog Manag Determine future plan for SSP owned equipment

30 Prog Manag Maintain a "Lessons Learned" list

Review both future customer and supplier contract to better protect SSP
31 Bus Dev
in the exit process
 APQP Deliverable Report Evidence

APQP DELIVERABLE DOCUMENTED EVIDENCE APQP Checklist Phase

1.        Project Timeline Complete Project Timeline defining, at a minimum, the Tasks associated with the
APQP Deliverables in this Status Report. Supplier Project Schedule must meet
1 defined milestones. 1
2 2.        Preliminary Bill of Materials (BOM) Preliminary Engineering or Manufacuring Bill of Materials 0
3.        Customer Inputs / Requirements Complete Customer requirements including Design Criteria, Program
3 Requirements 0
4.        Approved P.O. / Contract Supplier P.O. Acknowledgement (Contract Award Date to be shown in the Project
4 Schedule). 1
5.        Lessons Learned/Warranty & Quality Gap Analysis of Past Warranty & Quality Issues, Mitigation Action Plan (or Failure
5 Mitigation Plan Mode Analsis - FMA). 1, 2
6.        Prioritized Sourcing List / Sourcing Decision Approved Sourcing List Planned Sourcing Dates and Subcontractor Leadtimes to
6 be shown in Project Schedule) 1, 2
7.        Design Review(s) Final Design Review, prior to Production tooling launch with Minutes and Open
7 Issues 1, 2
8 8.        Prototype Control Plans Approved Prototype Control Plans AIAG Form 2
9. Design Failure Mode & Effects Analysis Production Level DFMEA with Pareto of High Severity/High RPN Items and
9 Completed Recommended Actions Customer
10.      Prototype Builds Prototype Part Delivery and Required Part Documentation per Prototype
Purchase Order (Project Schedule to include Prototype Part Design, Tooling,
10 Manufacture and Assembly). 2
11 11.     Design Verification Plan & Report (DVP&R) Approved DVP&R including Test Data and Closure of Design Review Issues 2
12.     Production Drawing & Specification Release Released Production Drawings and Specifications with Special (SRC, Major, etc.)
12 Characteristics Identified 2
13.   Critical Subcontractor APQP Reviews Initial Supplier APQP Status Report Matrix with Open Issues for all Critical to
Program Subcontractors. Supplier APQP Status Reports Samples with Planned
13 Timing Dates, Lead Responsibility and Program Need Dates. 3
14.     Process Design Review(s) Final Process Design Review, prior to Production tooling launch with Minutes and
14 Open Issues 2
15 15.     Pre-Launch Control Plan Approved Pre-Launch Control Plan 4
16.     Facilities, Equipment, Tools and Gages Facilities, Equipment, Tools and Gages complete and available (Project Schedule
to include Facilities, Production Equipment/Tools and Gage Design, Fabrication,
16 Qualification and Installation). 1, 2, 3, 4, 5
17 17.     Manufacturing Process Flow Chart Production Level Manufacturing Process Flow Chart 4
18.     Process Failure Mode & Effects Analysis Production Level PFMEA with Pareto of High Severity/High RPN Items and
18 Completed Recommended Actions 2, 3, 4
19 19.     Team Feasibility Commitment Completed Team Feasibility Commitment for Production Design 0
20 20.     Subcontractor Purchase Orders P.O's issued to Subcontractors with commitment dates for samples / PPAP 2, 3, 5, 6
21.     Subcontractor PPAP Approval Completed Critical Supplier APQP Status Report Matrix with Closed Issues and
21 Approved PPAP for Subcontractor Materials/Parts 3
22.     Measurement Systems Evaluation Matrix of GR&R, Calibration Results (including Bias, Linearity and Stability) and
22 Approval Date with Data Analysis Samples 3
23 23.     Operator Work Instructions Matrix of Work Instructions with Completion Status and Instruction Samples 2, 3, 4, 6
24.     Packaging Specifications & Approvals Packaging & Labeling Specifications and Evaluation Approvals with contingency
24 packaging plans 0, 2, 3, 6
25 25.     Manufacturing Team Training Manufacturing Team (Operators, Product Auditors, etc.) Training Records 1, 3, 4
26.     Production Trial Run Production Readiness Audit Results, Process Sign-Off Form or equivalent, Run at
26 Rate Data and Open Issues Matrix 4
27 27.     Production Control Plan Approved Production Control Plan 2, 4
28.     Process Capability Studies Matrix of Capability Results and Equipment / Tooling Approval Date with Data
28 Analysis Samples 2, 3, 4
29 29.     Production Validation Plan & Report (PVP&R) Approved PVP&R including Test Data 4
30 30.     Production Part Approval Process (PPAP) Approved PPAP Package (including Customer Approvals,) 1, 3, 4
31.     Initial Production Shipment Initial Production Shipment completed and Complete Shipping Documentation.
31 None
32 32.    Production Ramp-Up Plan Time period and rates of ramp-up to full production volumes None
33 33.    Full Production Date Production volumes achieved, all issues closed and project targets met 6
NOTE: A documented supplier Recovery Plan is required for any deliverable rated "Yellow" or "Red".