Professional Documents
Culture Documents
APQP
AIAG
Date of issuance:
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PMH
Content
1. Introduction
2. Program leader
4. PM Phases
5. Annex
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PMH
Content
1. Introduction
1.1 Validity
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Introduction
Validity
It can be found on Smartsheet and define the tasks of the program management department
and the function program leader within the context of the process and documents of the
program management organization PKC.
The aim is to ensure a successful, customer and target-oriented program coordination within
the framework of a international functional multi-program-management.
Torreón, in January 2022
1. Introduction
2. Program leader
4. PM Phases
5. Annex
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PMH
Content
2. Program leader
2.1 Responsibility
2.2 Competences
66
Program leader
Responsibility
General
Personal responsibility for planning and observance of deadlines, costs,…
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Program leader
Responsibility
Teamwork
Responsibility for a structured, active teamwork,…
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Program leader
Responsibility
Teamwork
The program leader should, as any other team member, stick to the rules of successful team work
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PMH
Content
2. Program leader
2.1 Responsibility
2.2 Competences
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Program leader
Competences
• Right to obtain information regarding all information from all departments which is
necessary to carry out the project
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PMH
Content
1. Introduction
2. Program leader
4. PM Phases
5. Annex
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Program vs. engineering change criteria
Flow
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3 4
6 Phase /
2 Gate Process
Program Difficulty Lvl 3
Program Assign ID & Add
Index GR G G
vs ECN to Program R4
1,2,3 3 R5
Register
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Program vs. engineering change criteria
Criteria
Objectives:
• Track each program on the Program Register – NO STEALTH PROGRAMS
• Walk each program through the difficulty index to identify level 3 programs
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Program vs. engineering change criteria
Cross functional teams
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PMH
Content
1. Introduction
2. Program leader
4. PM Phases
5. Annex
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AIAG
APQP
Customer
Milestones
PM Phases
documentation
PKC Gate Review
Quotation review
Advance comp. list
Phases Overview
Advance CAPEX
Financial model
Master plan draft
White paper application
Kick-off meeting
Start CER/RFA
Master plan detailed
Initiate change mgmt.
Submit CER/RFA
PFMEA
Equipment release
Line pre-release
GR3
R@R
VV
PPAP approved
Line release
GR4
Lessons learned
SOP
GR5
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Process
Process
Program
Continuous
PM Phases
Management
Improvement
PKC Gate Review
Quotation review
Advance comp. list
Advance CAPEX
Financial model
Master plan draft
White paper application
Kick-off meeting
Start CAPEX
Master plan detailed
Initiate change mgmt.
Submit CAPEX
Equipment release
Line pre-release
GR3
R@R
Engineering & QC Best Practices
PPAP approved
Line release
GR4
Lessons learned
GR5
PM Phases
Detailed levels
White
Quotation
paper
review
application
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PM Phases
Quoting
Quoting
Work out program basics in charge of the commercial department
Clarification of internal and external requirements.
Quoting preparation based on team inputs / afterwards: customer presentation
Customization of quoting in agreement with the customer and team.
Commercial
Kick-off meeting
Financial model
Cost Plant
Methods Develop-
estim. Eng.
lab ment
Purcha
PM
-sing
Quality
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PM Phases
Quoting
Quotation review Advance comp. list Master plan draft Advance CAPEX Financial model
To support team to To get information in To have a master List of tools, dies and Approved one (data and
secure all basic data in advance of all the checklist of program equipment used for percentages) for
order to provide optimal purchased components / activities / work financial model and CER/RFA submission
conditions for the raw material (new and packages to be used as CER/RFA submission. and for white paper
quotation creation before current) to order them in basis to create a Leader: Methods lab. application information
starting a program. advance and not to wait program timing. Leader: Leader: Commercial
Leader: Commercial until the prints are Program Management. department.
department. analyzed and BOM's are
set up. Leader:
Commercial department
& customer.
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PM Phases
Quoting
• Inform the team early about the new business and start officially the quoting phase.
• To collect the necessary data (regarding planning of milestones & costs).
Tasks
• Prepare quotation with the team approved inputs.
commercial
• Prepare rough planning (timing with support of PM, costs, requirements).
leader • Ensure updated documentations.
• Submit white paper application for approval and prepare the kick-off meeting.
• Quotation review
• Advance components list
• Advance CAPEX
Final • Financial model
documentation • Master plan draft
• White paper application
• Kick-off meeting = Gate Review 0
The quote can only be as good as the information provided by all the departments! Therefore, all data should be
investigated intensively & detailed – agreed in team.
Important The Whitepaper application must be provided before starting the planning phase, possibly with not finally
negotiated data. If at this stage the official business award is not available – the “Go” from top management is
necessary. After all the documentation is provided, the program leadership is transferred to Program Management.
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PM Phases
Planning
Planning
Ensure all necessary preparations for the project realization.
Establish a consequent change management.
Submit CER/RFA
Detailing of
Start CER/RFA
project planning
• Project plan
• Cost plan
• Resource
planning
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PM Phases
Planning
Start CAPEX Master plan detailed Initiate change mgmt. Submit CAPEX
Current CER / RFA To have a master To keep every change in Current CER / RFA
process performed early checklist of program the program ready in the process performed early
on time at the very activities / work latest version in order to on time at the very
beginning of the packages to be used as meet program targets beginning of the
program. Leader: basis to create a regarding program and program. Leader:
Program Management. program timing. Leader: product costs (and as a Program Management.
Program Management. base for a consistent and
reliable performance in
relation to the customer).
Leader: Program
Management supported
by commercial
department.
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PM Phases
Planning
Initiate change management
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PM Phases
Planning
Program Management department leads team to develop the master plan in detail.
• Start: after white paper application approved & kick-off meeting.
Planning
• End: CER&RFA submission
• Coordination of CER / RFA creation and submission with inputs from the quotation phase.
• Definition of prototype quantities.
Tasks program
• Detailed planning - Program plan based on the master plan
leader - Cost and resource planning
• Install change management (to avoid risk of loss).
• CER/RFA.
• Gate Review 1
Basis for the program plan creation is the PKC master plan.
In order to meet program targets regarding program and product costs (and as a base for a consistent and reliable
Important
performance in relation to the customer) it is essential to always keep every change request ready in latest version
– complete and reproducible!
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PM Phases
Prototyping
Prototyping
Systematic development and selection of constructive solutions.
Further development of already created conceptual drafts up to final release.
3D 2D
Design review start DFMEA DVP&R Technical review end Single part status
To track design status To start and keep To start and keep To track design status Second page of advance
and release. Leader: DFMEA updated. updated DVP&R and release. Leader: components list to track
Development Leader: Development Leader: Development Development the status of each
department. department. department department. component: MAPS,
PLEX, exception, PO,
ETA,… Leader: Program
management.
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PM Phases
Prototyping
Product concept realization and refinement (in drawings & BOMs) up to the product release (parallel: building of
corresponding prototypes).
Prototyping
• Start: after design review start (soonest during quoting phase).
• End: after technical review end & release.
Only intensive team work between R&D, prototype shop, manufacturing engineering regarding the feasibility
Important
studies and FMEA activities leads to a successful phase completion (special characteristics to be kept in mind).
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PM Phases
Line / Process definition
Equipment release
Methods Lab -16 steps
Line pre-release
Line review
PFMEA
Model line Mfg System
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PM Phases
Line / Process definition
Initial samples approval Line review PFMEA Equipment release Line pre-release
To assure samples To track manufacturing To start and keep To track the release To track manufacturing
availability and approval. line status & release. PFMEA updated. Leader: status of every involved line status & release.
Leader: Quality Leader: Methods lab Plant engineering machinery, tool,… Leader: Methods lab
department department. Same department. Leader: methods lab department. Same
document as line release department, quality document as line release
but in a different stage. department & plant but in a different stage.
engineering department.
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PM Phases
Line / Process definition
Securing availability of parts, equipment and production documents.
Line / Process • Start: after start of the planning phase
definition • End: after availability of the complete equipment, tools, dies,… and of all production documents for pilot run.
At the end of this phase all single parts have to be released. The line must be pre-released, just missing the R@R
Important
and full PPAP approval.
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PM Phases
Pre-production
Pre-production
Securing process capability, all releases & corresponding process optimizations.
PPAP approved
Train personnel
Line release
R@R
Initial sample releases
• Tool made sub assemblies and complete finished goods.
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PM Phases
Pre-production
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PM Phases
Pre-production
Securing process capability. Release of initial samples of tool-made parts (internal & external) and optimize
devices
Pre-production
• Start: after line pre-release
• End: line release.
• R@R documents.
• PPAP approved.
Final
documentation • Line release document.
• Gate Review 4.
Important At the end of this phase trainings for production employees / series conditions have to be intensified!
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PM Phases
Ramp-up
Ramp-up
Optimization of the process quality up to relief of program manager and team
Lessons learned
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PM Phases
Ramp-up
Lessons learned
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PM Phases
Ramp-up
Important Latest 90 days after customer SOP the project should be finalized.
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PMH
Content
1. Introduction
2. Program leader
4. PM Phases
5. Annex
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Annex
Program Management Handbook location / workspace
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Annex
Program Management Handbook sheet / documents
• On this sheet the Program Management Handbook is stored together with other documents related to the different
processes.
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PMH
Content
1. Introduction
2. Program leader
4. PM Phases
5. Annex
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