QUALITY MANAGEMENT SYSTEM PROCEDURE DOC. NO.

: QMSP/ 17
Issue No. & Dt. : 01 / 01.01.2015 ISO/IATF-16949 Clause Ref. :- 7.3.1,8.3

Rev. No. & Dt. : 02 / 01.07.2017 Page 1 of 7

Procedure: Process for Process Development Planning (APQP)

s1.0 Purpose

1.1 To establish a process for a structured system of up front Product Quality planning,
to support the development of product that will satisfy the customer’s quality
requirements before regularizing the production.

2.0 Scope

2.1 New Products or major modifications requiring major process changes

3.0 Input / References

3.1 “Advance Product Quality Planning Manual” Reference Manual

3.2 IATF 16949:2009 Element 8.3

3.3 Product Specification, Drawings

3.4 Manufacturing facilities.

3.5 Customers specific APQP manuals if any.

3.6 Customer’s specific requirement

4.0 Definitions / Abbreviations.

4.1 See Quality System Manual Section VII

5.0 Responsibility

5.1 Sample Development In-Charge

5.1.1 To prepare, review, update, and monitor this process

5.2 Management Representative

5.2.1 To approve, control, issue, retrieves this process.

6.0 Procedure

Cross Functional Team

6.1 PRODUCT DEVELOPMENT constitutes the Cross Functional Team and appoints
the Team Leader (SAMPLE Development In-Charge). The Team may include

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Issue No. & Dt. : 01 / 01.01.2015 ISO/IATF-16949 Clause Ref. :- 7.3.1,8.3

Rev. No. & Dt. : 02 / 01.07.2017 Page 2 of 7

Procedure: Process for Process Development Planning (APQP)

representative from Production, Quality Assurance, Purchase and operators if

required. Team may include representatives from customers or supplier if required.

6.2 Cross-Functional Team shall conduct the feasibility review and identify the special
characteristics.

Manufacturing Process Design Planning

6.3 Cross-Functional Team shall identify the various process development stages and
prepares the schedule / timing plan so as to meet commitments to customer.
The major stages shall include
 Raw Material specification and Suppliers
 Process Flow Chart
 Manufacturing Capability and the Floor Plan Layout Review
 Process Failure Mode and Effect Analysis
 Pre-Launch Control Plan
 Process Instructions
 Measurement system analysis plan and SPC plan
 Sample Development
 Production trial run
 Process capability study and MSA study
 Production validation and testing
 PPAP Approval
 Packaging Evaluation
 Production control plan
 Feed Back, Assessment and Corrective action

6.4 Manufacturing Process Design Input

6.4.1 Marketing In-Charge receives the drawings and customer specification and specific
requirements if any and issues to CFT.

6.4.2 CFT shall ensure the availability of the correct revision with respect to purchase
order.

6.4.3 CFT in consultation with Marketing In-Charge set the target for production per shift,
process capability required and the cost.

6.4.4 CFT shall check for the details available about previous similar products and data /
information shall be used while designing the process for the item.

Special Characteristics

6.4.5 CFT shall identify / define special characteristics based on

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Issue No. & Dt. : 01 / 01.01.2015 ISO/IATF-16949 Clause Ref. :- 7.3.1,8.3

Rev. No. & Dt. : 02 / 01.07.2017 Page 3 of 7

Procedure: Process for Process Development Planning (APQP)

Process FMEA
Customer’s requirement as indicated on drawings
Analysis of previous concerns
Regulations and statutory requirements

6.4.6 Not all products necessarily have special characteristics.

6.4.7 CFT shall ensure that special characteristics shall be included and identified either
by customer’s specific symbol or company specific symbols on all the relevant
technical documents and control plans.
6.5 Manufacturing Process Design Output.

6.5.1 CFT shall finalize following documents and compare with process inputs.

 Raw Material specification and Suppliers

 Process drawings where ever required
 Manufacturing Process Flow Chart
 Manufacturing layout (if existing layout needs to be changed)
 Manufacturing Process Failure Mode and Effect Analysis
 Pre-Launch Control Plan
 Process / Work Instructions / Process parameters
 Acceptance criteria for process control
 Measurement system
 Packaging Evaluation
 Production control plan
 Feed Back, Assessment and Corrective action
 Data for quality, reliability, maintainability and measurability.
 Methods for rapid detection and feedback of product / manufacturing process
nonconformities.

6.5.2 CFT shall also decide on

 Error proofing methods

 Level scheduling
 Pull system inventory control
 Single piece flow
 Visual controls
 Work place organization and layout

6.6 Manufacturing Process Design review

6.6.1 Cross functional Team along-with SAMPLE DEVELOPMENT shall review the
progress as per APQP Schedule
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Issue No. & Dt. : 01 / 01.01.2015 ISO/IATF-16949 Clause Ref. :- 7.3.1,8.3

Rev. No. & Dt. : 02 / 01.07.2017 Page 4 of 7

Procedure: Process for Process Development Planning (APQP)

 To evaluate the ability of the results of Process Design and Development

Process to meet the requirements

 To identify any problems and propose necessary actions

6.6.2 The CFT shall review the manufacturing process during production trial run and
initiate changes or corrective action if required.

6.7 Manufacturing Process Design Verification

6.7.1 Cross functional Team along-with Development In-Charge shall verify the process
design by

 Checking with similar component process

 Similar tools
 Experiences on previous components / failures

6.8 Production Process Validation and Testing phase

6.8.1 Sample Development

Samples of the components are developed by the Production Department, the

required testing is carried out as per the Control Plans and the samples of the same
are submitted to the customer for the approval by the Marketing In-Charge /
Development In-Charge. The Marketing In-Charge / Development In-Charge follow
up with Customer for approval of the same and feedback obtained from the customer
is reviewed by the CFT.

The samples submitted as per the above paragraph is termed as Pilot Samples; the
size of the sample batch is as decided by the customer / CFT. This process is
carried out, whenever the customer doesn’t place the order for PPAP Batch.

6.8.2 Production trial run

The production trial run is carried out using the production tooling, equipment, and
environment (including production operators), facility and cycle time.

The minimum quantity for production trial run is usually set by the customer but can
be decided by the CFT Initial production batch will be monitored separately for
30,000 no’s or 3 Months. Initial Batch to be monitored with separate identification tag
& separate location.

6.8.3 Process capability study and MSA study

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Rev. No. & Dt. : 02 / 01.07.2017 Page 5 of 7

Procedure: Process for Process Development Planning (APQP)

The studies as planned for the SPC are carried out by the QA In-Charge and the
result of the same are analyzed by the CFT.

QA In-Charge shall conduct MSA studies and the results of the same are analyzed.

6.8.4 Production validation and testing

QA In-Charge carries out the required inspection and testing of the products as per
the control plans and the results of the same are documented.

6.8.5 PPAP

QA In-Charge and Development In-Charge complete all the activities and prepare
documents as required in PPAP. If required by the customer the same is submitted
for his approval, if not the same is retained at our end.

6.8.6 Packaging Evaluation

The packing of the finished components is carried out as per the documented
instructions by the Stores In-Charge. The evaluation is carried by assessing
damages occurred during the transportation of the goods to the customer and
feedback from the customer.
QA In-Charge and Stores In-Charge jointly carry this out and the results of the same
are reviewed along with the CFT.

6.8.7 Production control plan

QA In-Charge shall prepare the control plan based on experiences during the
Production trial run stage, feed back from the customer and the same is reviewed
along with the CFT.

6.9 Feed Back, Assessment and Corrective action

6.9.1 QA In-Charge obtains necessary feedback from the customer on the performance of
the products in the customer’s manufacturing line; the details of the feed back are
reviewed along with the CFT members.

6.9.2 The changes initiated by the customer (or by company to achieve customer
satisfaction) are reviewed, documented and implemented as per the documented
procedures for Document and Data control, Process control and PPAP.

6.9.3 The QA In-Charge maintains the record of the Changes and Part approval in the
respective PPAP file of the Part Number.

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Issue No. & Dt. : 01 / 01.01.2015 ISO/IATF-16949 Clause Ref. :- 7.3.1,8.3

Rev. No. & Dt. : 02 / 01.07.2017 Page 6 of 7

Procedure: Process for Process Development Planning (APQP)

6.9.4 The CFT initiates the Continual Improvement projects on the Special characteristics
wherever the necessary stability and capability are to be achieved. This is primarily
to improve the value of our service to the customer.

6.10 Service Agreement

6.10.1 Presently there are no service agreements for any customer.

6.11 Safety Related Product

6.11.1 Presently there are no product-safety related parts for any customer.

6.11.2 Where applicable; Development In-Charge maintains as follows-

 Identification of statutory and regulatory product-safety requirements with customer
notification of requirements
 Identification of product safety-related characteristics
 Identification and controls of safety-related characteristics of product and at the point
of manufacture
 Special approval of control plans and process FMEAs and reaction plans (if asked by
customer)
 Escalation process and customer notification for any failures
 Training requirements
 Control over out-sourced
 Traceability requirements.

7.0 Measurements and Monitoring of Process

7.1 No. of Components Developed

7.2 No. of PPAP submitted

8.0 Records

8.1 Product requirement Review

8.2 APQP Time Plan

8.3 Process Flow Diagram

8.4 Process Failure Mode and Effect Analysis

8.5 Control Plan

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Issue No. & Dt. : 01 / 01.01.2015 ISO/IATF-16949 Clause Ref. :- 7.3.1,8.3

Rev. No. & Dt. : 02 / 01.07.2017 Page 7 of 7

Procedure: Process for Process Development Planning (APQP)

8.6 Engineering Change

8.7 APQP Review Records

8.8 List of Active Parts

8.9 Customer purchase Order

8.10 Part submission Warrant

9.0 Modifications

01.07.2017 01 Clause no 6.10 &6.11 add

Date Rev No Amendments Details

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