AXIOM GROUP INC.

Advanced Quality Planning (AQP) Page 1 of 7

Prototype/Product Development AQP - Phase 2

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INTRODUCTION

The second phase in a project is Prototype and/or Product Development. During this period of
time, design features and characteristics are developed into a feasible and final form.

In most cases prototype tooling is required to produce production representative products to

satisfy internal and/or external design validation, functional and process evaluations.

The inputs and outputs relevant to this phase may vary depending on the situation, needs and
wants of both the customer and the company.

2.1 Design Review - Initial Concept

The purpose of Initial Concept Review is to familiarize the team with the product and its
requirements.

During the design review, tooling (design for manufacturing) considerations must be taken into
account and addressed.

The suggested attendees for design reviews are:

 Board of Directors Member

 Program Manager
 Quality Assurance Manager
 Subcontractor
 Engineering Manager
 Tooling Supervisor

Typical inputs to the Initial Concept Design Review include but are not limited to:

 Product design and functional requirements

 Drawings provided by the customer.
 Technical Specifications
 Equipment, Tooling and Facilities Requirements
 Program timing requirements
 Risks and opportunities associated with the above items

Reviews must be documented with meeting minutes (QAR-5.0.1). Issues arising from reviews
are officially open and in all cases must be documented. All open issues must be addressed and
eventually closed.

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Date Issued: November 17.2021 Revision Number: 13
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Prototype/Product Development AQP - Phase 2

2.2 Key Characteristics Defined

Special characteristics indicated by the customer must be reviewed in order to assess

manufacturability and process capability (i.e. Cpk/Ppk=1.67 or Cpk/Ppk=1.33). Special
characteristics can be related to the product or process. It is particularly important to obtain
internal plant manufacturing and quality feedback prior to making commitments to the customer.
When required by the customer, their forms must be used to document the agreed upon
requirements.

An internal key characteristic is defined as a process or product characteristic that shall be

included in the PFMEA and Control Plan because it affects fit, form, function or appearance, or is
sensitive to process variation. Symbols are not used to identify these key characteristics.
All key characteristics are recorded onto the Key Product/Process Characteristics List, All CIC's
and PTC's must be included (If it is required) (QAR-8.3.18).

MSA- All gauges used to measure key characteristics shall be subject to the appropriate MSA
studies.

Initial Process Study- Initial process studies shall be conducted on at least one key characteristic,
as agreed upon by the APQP team. Ppk studies shall be conducted on variable gauges used.
Attribute studies shall be conducted on attribute gauges used. The sample size shall be agreed
upon by the APQP team.

2.3 Engineering Specifications Documentation

All applicable Engineering Specifications designated by the customer as a requirement must be

obtained and retained for reference. Examples include testing, paint, performance and design
specifications. Any deviations from Engineering Specifications must have written approval from
the customer.

2.4 Material Specifications Documentation

All applicable Material Specifications designated by the customer as a requirement must be

obtained and retained for reference.

2.5 CAD Design Started

This is the date that tool design development begins at sub-contractor.

2.6 Design Freeze

The design freeze date is the date published to product/tooling design, beyond which no further
change in current design direction can be made without impacting program timing and/or cost.
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Prototype/Product Development AQP - Phase 2

2.7 Engineering Bill of Materials Complete

The program manager shall review the completed list of components, assemblies and part
numbers required for the product.

2.8 DFMEA Complete

The team consisting of the Program Manager, Engineering Manager & Tooling Supervisor shall
complete the Design Failure Mode and Effects Analysis (DFMEA) (QAR-8.3.1). Completing
the DFMEA is the first major step in identifying and/or qualifying characteristics to control in the
manufacturing process.

The DFMEA is a living document and as such, it should continue to be updated throughout the
program, particularly as manufacturing inputs become available.

Axiom Group Inc.’s policy is to demonstrate RPN reductions in the DFMEA development. The
following criteria have been established to determine the need for action:

1) If severity is 9 or 10 and the RPN is greater than 120.

2) If severity is 7 or 8 and the RPN is greater than 160.
3) If severity is 6 or less and the RPN is greater than 165.

As per the above criteria, the team must demonstrate reductions in the overall RPN total by
completion of the DFMEA by the end of Phase 2 of the program.

2.9 Equipment, Tooling and Facilities Requirements

A list of all equipment, tooling and facilities needed to successfully produce

prototypes/production parts must be completed (QAR-8.3.8).

The team must review the listing and compare it with the quoted requirements. If these
requirements do not agree with the quoted items, a Discrepancy Report (QAR-8.3.4) must be
submitted to Board of Directors to initiate corrections to the quotation.
If possible and where appropriate, identify preliminary calibration and preventive maintenance
requirements; otherwise, provide this information at a future date.

2.10 Design Review – Prototype/ Production Tooling Release Level

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Prototype/Product Development AQP - Phase 2

The team must schedule and conduct design reviews on a regular basis as dictated by the
customer and/or the AQP schedule. The purpose of Prototype/Production Tooling Release Level
Review is to familiarize the team with the product, as it will be released for tooling.

The suggested attendees are:

 Board of Directors Member

 Sub-contractor
 Program Manager
 Quality Assurance Manager

Typical inputs include but not limited to:

 Product design and functional requirements (V.O.C. and internal)

 Preliminary Prototype Release drawings
 Bill of material
 Equipment, Tooling and Facilities Requirements.
 Program timing requirements
 Risks and opportunities associated with the above items

Reviews must be documented with meeting minutes (QAR-5.0.1).

2.11 Design Release

The release date of approved toolable CAD data to tooling and/or the customer.

2.12 Kick-off Tooling

Program manager will establish a date to start building tool, where new tooling is required. The
date that tool maker(s) is given the appropriate approval to begin tool design and manufacturing.

2.13 Kick-off Gages

The date that the gage maker(s) is given the appropriate approval to begin the design and building
of gages. Refer to the APQP – Gauges and Test Equipment (QAR-8.3.19).

2.14 Kick-off Test Equipment

The date that test equipment manufacturer(s) is given the appropriate approval to begin the design
and building of test equipment and fixtures.

2.15 Gage Design Approval

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Prototype/Product Development AQP - Phase 2

The date that gage design are approved as per project requirements.

2.16 Test Equipment Design Approval

The date that test equipment and fixture design are approved as per customer requirement.
2.17 Detail Prints Released

The date that approved detail (component) prints are released..

2.18 Assembly Prints Released

The date that approved assembly prints are released.

2.19 Pre-launch Control Plan Complete

As per customer requirements the team shall prepare pe-launch control plans (QAR-8.5.0). These
plans are intended to provide a description of the dimensional measurements, material and
functional tests that will occur during pre-launch phase..

2.20 Supplier Selection Complete

A list of component suppliers shall be prepared by Purchasing Manager or designate (QAR-

8.3.8).

2.21 Order Components & Material

This is the date that components and materials must be ordered to ensure timely delivery of
materials for the prototype/product build. The orders must be documented with Purchase Orders
(QAR-8.4.0).

2.22 Components & Material Receiving Date

This is the date that all components and materials must be received in order to successfully begin
the prototype/product build process on schedule. The date must be scheduled such that adequate
time is allowed for qualifying the components and materials prior to the build as applicable.

2.23 Tooling Delivered

The dates that tooling and fixtures must be received in order to successfully begin the
prototype/product build process on schedule. The date must be scheduled such that adequate
time is allowed for qualifying the equipment and fixtures prior to the build as applicable.

2.24 Gages Delivered

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Prototype/Product Development AQP - Phase 2

The dates that functional gages must be received in order to successfully begin the
prototype/product build process on schedule. The date must be scheduled such that adequate
time is allowed for qualifying the gages prior to the build as applicable.

2.25 Test Equipment Delivered

The dates that functional test equipment and fixtures must be received in order to successfully
begin the prototype/product validation on schedule. The date must be scheduled so that adequate
time is allowed for qualifying the equipment and fixtures prior to the start of testing as applicable.

2.26 Tooling 1st Trial

This is the date that the first part shall be made from prototype/production tools. The date must
be scheduled such that adequate time is allowed for qualifying tools prior to the build as
applicable.

2.27 Dimensional Validation Complete

This is the date that the required dimensional reports must be completed. Action plans must be
developed to resolve any out of print dimensions that are discovered and reported unless
otherwise agreed to in writing by the customer with the authority to do so.

2.28 Testing Validation Complete

This is the date that validation testing per the design validation requirements must be completed.
Test reports must be generated to document the results for review and future reference. Action
plans must be developed to resolve any failures that are discovered and reported unless otherwise
agreed to in writing by the customer with the authority to do so.

2.29 Prototype/First-Off parts at Customer Location

This is the date that the customer requires the first prototype/first-off parts to be delivered and
received at the specified ship point. The scheduled date is the date the customer requires. The
actual date is the date the parts were received.

2.30 Evaluation Review

The purpose of Evaluation Review is to review the performance of the product as designed.
During the design review, tooling (design for manufacturing) considerations must be taken into
account and addressed.

The suggested attendees are:

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Date Issued: November 17.2021 Revision Number: 13
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Prototype/Product Development AQP - Phase 2

 Board of Directors Member

 Sub-contractor
 Program Manager
 Quality Assurance Manager
 Customer

Typical inputs to the Evaluation Review include but are not limited to:

 Feedback from the customer.

 Fit, function and appearance feedback
 Validation testing reports
 Dimensional reports
 Manufacturing feedback from primary and secondary tooling and the plant
 Program timing requirements

Open issues and action plans to revise the design for future events must be documented.

Reviews must be documented with meeting minutes (QAR-5.0.1).

2.31 Upper Management Approval - Phase 2

When all the phase 2 items are closed, management must review the outputs of the team and
approve the completion of the phase or recommend further actions required to achieve
completion (QAR-5.0.1). This review must be completed by the end of Phase 2 for any direct
programs with Daimler Chrysler, Ford or General Motors.

UNSIGNED PRINTED COPIES ARE UNCONTROLLED DOCUMENTS

Date Issued: November 17.2021 Revision Number: 13