(APQP) And Control P!

a>

APQP
Second Edition

Quality Management
PPAP in the Supply Chain

TRAINING:

■ APQP / VDA-MLA (Advanced Product Quality Plan)

■ PPAP / VDA-PPA (Production Part Approval Process)

November 2019
CONTENT

AIAG APQP-PPAP

Advanced Product Quality Planning

(APQP) And Control Plan
Production Part Approval Process
APQP PPAP
Second Edition Fourth Edition

2
CONTENT

VDA Maturity Levels (APQP) and VDA2 (PPAP)

2
VDA Verband der
Automobilindustrie

Quality Assurance for Supplies Joint

Quality Management
in the Supply Chain
Product creation
• Maturity level assurance for new parts

- Methods, measurement criteria, documentation -

2nd
revised edition, October 2009

English version published in July 2010

3
Index
> IATF 16949: 8.3 Project Management
> AIAG APQP Advanced Product Quality Plan
> AIAG PPAP Production Part Approval Process
> VDA MLA (APQP) Maturity Level Assurance
> VDA2 PPA (PPAP) Approval of production, product and
process
> Other issues to consider in project management

4
 Audit, Consulting and Training

5
 IATF16949 REQUIREMENTS FOR PROJECTS

IATF 16949:2016

STANDARD OF IATF 16949:2016

QUALITY MANAGEMENT SYSTEM
OF THE AUTOMOBILE

Quality management system requirements for organizations producing

automotive parts and spare parts

International Automotive Task

Force

1* Edition 1
October 2016

6 MANAGE
Audit, Consulting and Training
MENT
AQP
Q
AIAG APQP-PPAP
Advanced Product Quality Planning
(APQP) And Control Plan

APQP
Second Edition

APQP 2nd EditionCore

tools (AIAG)

7
AQP
Q
CONCEPTS: APQP + PPAP
■ APQP Concept ■ PPAP concept
APQP (Advanced Product Quality Production Parts Approval of
Planning) is a structured method of Process defines the parts th
defining and establishing the approval requirements e
measures necessary to ensure that a production, for of
product satisfies the customer. Design, AMFE´s, ControlRecords
including plans,
SPC's, MSA´s, Results
The objective of the APQP is to Dimensional, Chemical, Appearance,
facilitate communication with all those etc., Raw Material Registration,
involved. ensuring Qualified Laboratories, Samples,
the Measuring Equipment and Supplies,
planning for achieve the IMDS, Etc…
customer satisfaction in product
design and manufacturing.

■ APQP Processes
(Phases)

MANAGE
Audit, Consulting and Training
MENT
AQP
Q
APQP PROCESS
1. Plan and define
APPROVAL OF THE
the APQP
PROGRAM
2. Product Design and Development
PROTOTYPE PILOT LAUNCH

LANEATIO 3. Design and Development of

N the Process

PRODUCT DESIGN PLANNING

AND DEVELOPMENT 4. Product and
Process Validation

PROCESS DESIGN AND DEVELOPMENT

5. Feedback,
Evaluation and VALIDATION
PRODUCT AND PROCESS
Corrective Action

PRODUCTION

EVALUATION AND ACTION FEEDBACK CORRECTIVE

9
 APQP PROCESS
AQP
Q 2. 3. Design 4. Product 5. Feedback, —>
0. APQP 1.Plan and define
Fundamentals the APQP Product and and Evaluation and Corrective
Design Development Process Action
and of Validation
Development the Process

•Organize Team 1. The voice of the 7. Design 1. Design Failure 1. Packaging 1. Production 1.Variation
customer objectives Mode and Effects Standards Test (pre- reduction
•Define the scope of 2. Business Plan / Analysis (D-FMEA) series)
application Marketing Strategy 8. Reliability 2. Review of the 2. Customer
and Quality 2. Design for Product/Process 2. Evaluation Satisfaction
•Establish team- Objectives manufacturing and Quality System Analysis of
to-team 3. Product/Process 3. Delivery
assembly Measurement
communication Benchmarking 9. 3. Design Verification 3.Process Flow and Service
System
Preliminar Diagram 3.Study of
•Training 4. Product and 4. Design reviews
y Bill of Preliminary
Process 4. Floor plan
•Involve Materials 5. Construction Processing
Considerations 10. Preliminary
customers and
suppliers 5. Product
Process Flow Chart
Prototype - Plan of
Control • 5.Features
Capability
4. PPAP: vi Part
MSA
reliability Matrix
•Implement 6. Engineering Approval and
studies 11. Preliminary list
simultaneous plans drawings 6. Process Failure Production
of critical
engineering 6. End- (including Data) Mode and Effects Validation
characteristics of the
customer Analysis (PMEA)
•Develop Plan product and process 7. Engineering
inputs
Format Specifications 7. Pre-launch Control 5. Packaging
12. Product
Control Plan Evaluation
Assurance Plan 8. Material
•Problem specifications 8. Process 6. Production
Resolution Instructions Control Plan
13. 9. Changes to
•Develop the Management Drawings and 9. Measurement 7. Closing of the
Planning of the
APQP
Support Specifications Systems Analysis
Plan
APQP PPAP
10.New equipment,
•Plans related to tools and facilities 10. Preliminary
planning Process Capacity
Study Plan
AMFE 11.Critical
Characteristics of 11.
Product and Process Management
Support
12.Requirements for
gauges and
SPC
QFD measuring equipment
13. Feasibility, Plan of
commitment and
management team
Control
1
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MANAGE
Audit, Consulting and Training
MENT
AQPQ Example: Injection Project Phases – I

1
1
1
2
AQPQ Sample Project Plan
PHASE NO. PHASES STAGE NO. STAGES CHECK LIST STAGE MANAGER EXPECTED DATE CLOSING DATE STATUS
100 Offer 100 Data entry 2D plane
3D Geometry
Specifications / Standards Part
Sample piece
Other documentation
110 Offer Implementation / Feasibility Realization Feasibility
Execution of Offer (bill of quantities)
Sending Offer / feasibility to client
120 Offer Status Offer accepted
Offer rejected
Client contract
Communication Offer accepted Projects
200 AMFE 200 FLOW / AMFE FLOW
FMEA implementation
Control plan Preliminary phase
300 Mold construction 300 Contract with the supplier sent Contract to moldist
Reception of signed contract
310 Mold Design Review of preliminary draft
Final Project Review
320 Mold Construction Machining
Mold test
Modifications
Finished mold
400 First Samples 400 Purchasing / Supply MP - Components MP / component purchases (see MP homologation - components)
MP delivery / components under test + certificates / technical sheet
410 First samples in moldista nº Sample pieces
Mold test checklist
Dimensional control / appearance
Sending sample parts to customer
Customer sample validation
420 First samples on floor no. Sample pieces
Mold test checklist
Dimensional control / appearance
Mold test checklist
Cpk Capacity Studies
430 Validation of first samples Validation First customer samples
Pattern Piece Customer Validated Sample
440 Mold Maintenance Mold Sheet
450 Machine maintenance / Utilities Machine / Tool Sheet
500 PPAP 500 PPAP Quality 4 FLOW
5 AMFE Final
Final Control Plan
Reception control guideline
Injection control guideline / Defects catalogue
Intermediate packaging guidelines
Final packaging guidelines
Raw material certificate
IMDS
Dimensional control / Testing
Appearance Approval Report
Capacity Studies (Cpk)
Measuring/Test Gauges (calibration - verification)
Documentation of Qualified Laboratories
MSA Studies Analysis of measurement systems
Capacity Studies (CPk)
600 Pre-series / PPAP Delivery 600 Pre-series validation Production realization
Pattern Piece
Capacity Studies
Ckeck list 2TP (Preseries validation)
610 PSW Component OK Submit or fill out PSW / ISIR / Customer requirement for homologation
Pattern Piece Suppliers
PSW/ISIR signed components
620 PSW / ISIR / Customer requirement for homologation Submit or fill out PSW / ISIR / Customer requirement for homologation
Delivery of client documentation
Validation of departments involved
PSW/ISIR signed client
700 SOP Series Manufacturing 700 SOP Series Manufacturing Manufacturing order number
800 POST-SOP 800 PCOS assessment (6 months) Verification of offer
Production Capacity Studies (Cpk)
Product Audit
NC Closure of Internal Product / Customer Complaint

1
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AQPQ Sample Project Plan

1
4
PPA
P
AIAG APQP-PPAP

Production Part Approval Process

PPAP
Fourth Edition

APQP 4th EditionCore

tools (AIAG)

1
5
PPA
P

1
6
PPA
P
PSW (Part Submission Warrant) /
Presentation of Homologation
—
Name of piece___________________________________________ N2 Customer piece
Shown on Plan No. _______________________________________ N2 Organization piece

Engineering Change Level Date

Additional Engineering Changes Date
Security and/or Government Regulations • Yes □ No No. Purchase Order Weight kq

No. Useful Check ___________________________ Engineering Level of Verification Tool______________________________ Date______________

ORG. INFORMATION PRODUCTION PLANT CUSTOMER INFORMATION TO PRESENT

Supplier Name and Supplier/Seller Code Client Name / Division

Address Buyer / Buyer Code

Population Application (Model-year, vehicle name, engine, transmission, etc.)

Region Zip code
Country
MATERIALS REPORT □ Yeah □ No □ N/A
Has the client requested reporting of Substances of Concern?
Submission by IMDS or other client format:

LOGO Homologation Document

Are polymeric parts identified with the appropriate ISO codes? • Yeah
(PSW)
□ No □ N/A

REASON FOR PRESENTATION (Choose at least one option)

• Initial Presentation • Change to Optional Construction or Material I | Change of
• Engineering Change(s) Supplier or Material Source
• Tools: Transfer, Change, Rehabilitation or Additional
• Correction of Discrepancy(ies) • Change in the Part Process
• Inactive Tooling > than 1 year II Pieces Produced in Additional Plant
• Other - please specify:

REQUIRED PRESENTATION LEVEL (Choose one)

• Level 1 – PSW only (and for defined appearance aspects, an Appearance Approval Report), submitted to client.
□ Level 2 - with limited product samples and supporting data, presented to client.
• Level 3 – PSW with product samples and complete supporting data, presented to client.
□ Level 4 - PSW and other requirements, as defined by the client
• Level 5-PSW with product samples and complete supporting data, reviewed at the organization's production facility.

RESULTS OF THE PRESENTATION

The results of •dimensional measurements •functional and material tests •appearance criteria •Statistical Process Assembly stico These results meet all the
requirements of plans and specifications: • Yes • NO if "NO" - Explanation Required)

Mold / Cavity / Production Process

STATEMENT
I affirm that the samples represented in this PSW are representative of our parts, which were made with a process that meets all the requirements of the PPAP Manual 42 Ed.
I further affirm that these samples have been produced with the production cycle / hours using hours of usual production

I also certify that documented evidence of such compliance is on file and available for review. Below I note any deviations from this statement.

EXP PL ICATI ON/ COM ME NTARY S ________________________________________________________________________________________

Is each Customer-owned Tool labeled and numbered? Yes □ No □ N/A

Authorized Signature of the Organization Date

Name No Phone No Fax
Function e-mail:
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Part Approval: • Approved • Rejected • Other:

Client Signature Date

Name Customer Traceability Number (optional):

1
7
1 Scheme
Complexity (type and number of functions, level of system Integration, number of variants, number of
departments Involved)
Product Innovation (concept, design, material; function;
appearance; feel 1
Critical problems In the past (held rejects, in-house
problems)

V Development ettort (expertse; cirterent development areas

involved)

D
Joint 0ulily
Predicted process stability .level ot automaton; manual production production system
scrap leveis
Production facility, machinery

Athe Supply
Management
in
technology
ntrostructure (re number year compicxty of sub suppliers location.
logici3ticsi
Chain Delivery call oft times (comoination of long transport dclancos range of variants. JIT JIS colvoriog, several
dolivory locationo
Procurement times for production tactility and machines. It appropriate, related to the date for
piecing the order
Procurement times lor tools, it appropriate, related to the date lor placing
the order
Procurement times lor parts and basic
materials

Frequency of changes (effects on / by other dolivorod producís dependency on

design and system)
Supplier assessment (new supplier, reliability of deliveries, overall reliability, sub-
supplier management)

VDA "
Maturity Level Assurance" (MLA)

14

14
COMPARISON OF PPAP WITH
VDA2
VDA PPA: AUTOMOTIVE STANDARD

1
9
Audit, Consulting and Training
COMPARISON OF PPAP WITH
VDA2
VDA 2 PPA: Cover
Sender Recipients:
oo
Process-Product Acceptance Report Presentation level: 2
Other sample reports o New presentation of samples
or Samples o Production suspended for more
x New piece 12 months
-- o Product modification o Changes in the supply chain
o Changes in the production process
Attachments / to be reviewed
Product / Process
either 1.1 Geometry, Dimensional Testing either 1.9 ESD Test either8 Software Testing either 16
Report of State of Useful Items
either 1.2 Rehearsal Functional either 1.10 Essay of Reliability either9 AMFE Process either 17
Evidence of Agreed Capacity
either 1.3 Rehearsal Materials either 2 Sample / Pattern either 10 Process Flow Diagram either 18
Self-control instruction
either 1.4 Rehearsalof perception (appearance, touch) or 3 Specs techniqueseither 11 Product Control
Planeither 19 History of the Piece
either 1.5 Rehearsal Acoustic either 4 FMEA Product either 12 Process Capability Testing either 20
Transportation Aptitude Test Incl. store
Supplier data
Supplier / Production Plant: Delivery note No.: Customer
ID No./ DUNS Code: Quantity delivered ID No:
Report No.: Index: Lot No.: Report No.: Index
Denomination: Sample weight: Denomination:
Customer Reference: Entry delivery note number / Date: Customer Reference:
Plan No.: Order No. / Date: Plan No.:
State: Date: Delivery destination: State: Date:
Supplier Confirmation: - We hereby confirm that the submission of samples has been carried out in accordance with VDA Volume 2
Name Phone Fax: - The IMDS data record has been created under IMDS
No.:
Yes or no:
Department
Observations: E-mail: Date: CCC marking required or
Signature:

Customer decision: Approvals

Product / Process
Total Total (N C IT eit C EI eit C EIT ei eit C EI C ( WI

1.10
Total 3. S he M O OJ co F IT • OJ co N IT he N OJ TH

02
Process Product O TH her O HER
th O T Ñ
eith r
eit eit eit ei eit eit eit ei ER r
eit eit eit eit eit ei eit eit eit eit ei eit ei eit ei eit eit eit ei eit eit eit eit eit
OK either either
er he he he th he he he th he he he he he th he he he he th he th he th he he he th he he he he he
Conditional approval, new sample submission either eith either eit eit eit ei eit eit eit ei eit eit eit eit eit ei eit eit eit eit ei eit ei eit ei eit eit eit ei eit eit eit eit eit
required er he he he th he he he th he he he he he th he he he he th he th he th he he he th he he he he he
NOK - New sample submission required eith eit eit eit ei eit eit eit ei eit eit eit eit eit ei eit eit eit eit ei eit ei eit ei eit eit eit ei eit eit eit eit eit
either either
er he he he th he he he th he he he he he th he he he he th he th he th he he he th he he he he he
No. Approval Deviation: Valid until: No. of pieces: Deadline for new submission In case of return delivery note number / Date:
Name Phone Fax: -
Department E-mail:
Observations: Date: Signature:

5
Distribution list 1 2 3 13
14 6 7 8 14
9
1 10 1 11 1 12 1

2
0
COMPARISON OF PPAP WITH
VDA2

2
1
COMPARISON OF PPAP WITH
VDA2
VDA 2 PPA: Detailed presentation report
Supplier / Production Plant: Customer Supplier 7 production location Customer
Ref. No. DUNS code: Ref. No.:
ID No./ DUNS Code: ID No: to be comceled b,
Report No.: Index: Report No.: Index: ehe custoerar
Report No.: Index Report No.: Index
Plan No.: Title: Drawing No.:
Denomination Index/date:
Part No.
Client Reference State: Date:

Status/ Type, quantity and identification of Issue Type, extent and

Exhibit
Date: attachments Appendix level/dat Identification of the
o 1.1 Geometry, Dimensional testing e appendix
o 1.2 Functional Test □ 1.1 Geometry, dimensional check
o 1.3 Test Materials □ 1.2 Function check
o 1.4 Perception test (appearance, touch) • 1.3 Mother check
o 1.5 Acoustic Test □ 1.4 Haptic check
□ 1.5 Acoustics check
o 1.6 Odor Test
□ 1.6 Odour check
o 1.7 Visual appearance test
□ 1.7 Appearance of shock
o 1.8 Surface Test
□ 1.8 Surface check
o 1.9 ESD Test □ 1.9ESDtest
o 1.10 Reliability Test □ 1.10 Reliability tests
or 2 Sample / Pattern □ 2 Samples
or 3 Technical specifications □ 3 Technical specifications
or 4 AMFE Product □ 4 Product FMEA
o 5 Design approval □ 5 Design release
o 6 Compliance with Legal Requirements □ 6 Compliance with legal requirements
o 7 IMDS / Material Data Sheet □ 7 Material data sheet / IMDS
or 8 Software Essay □ 8 Software test report
or 9 AMFE Process □ 9 Process FMEA
□ 10 Process flow diagram
o 10 Process Flow Diagram
□ 11 Control plan
o 11 Product Control Plan
• 12 Confirmation of process capability
o 12 Process Capability Test □ 13 Achievement of special characteristics
o 13 Special Features Control □ 14 Test/Inspection equipment list
o 14 List of Control Media O 15 Capability study testing equipment
or 15 Test Equipment Capacity □ 16 Tooling list
o 16 Utility Status Report □ 17 Confirmation of agreed capacity
o 17 Evidence of Agreed Capacity □ 18 Written self-assessment
o 18 Self-control instruction □ 19 Part history
or 19 Historical Piece
or 20 Transportation Aptitude Test Incl. storage □ 20 Confirmation of suitability of transport equipment
or 21 PPF Supply Chain Status □ 21 PRA status of tho supply chain
o 22 Release of Laminating Systems □ 22 Approval of coating systems
or 23 Others
□ 23 Others
Comments by supplier:
Supplier Observations Yam:
Name Depl.:
Department Telephone:
Phone Fax:
E-mail:
Fax: -
Date: Signed:
E-mail:
Date: Signature:

2
2
COMPARISON OF PPAP WITH
VDA2
VDA 2 PPA: Detailed report on presentation of test results
Product-related test results issue: — / Dale:. □ □
Sheet____of
□ □
□ 1.1 Geometry; dimensional checks □ 1.9 test
□ 1.2 Function checks □ 1.10 Reliability checks Confirmation by supplier: Decision by customer:
□ 1.3 Material checks □ 2 Samples Comments:
□ 1.4 Haptic checks □ 3 Technical specifications
Released
Rejected; reapproval of PPA
□
□ 1.5 Acoustics checks □4 Process is required
□
□ 1.6 Odour checks • 5 Design release Comments:
□ 1.7 Appearance checks □ 6 Compliance with legal requirements
□ 1.8 Surface checks • 7 Material data sheet / IMDS

Yam: Yam:
Supplier/production location: Customer: Dept.: Dept.:
Telephone: Telephone:
ID No. / DUNS code: ID No.:
wohecompnted by
Fax: Fax:
Report No.; Index: Report No.: Index: Eetemar E-mail: E-mail:
Date: Signed Dale: Signed.
Description: Description:
Part No.: Part No.: 1.1 Geometry, Dimensional Testing STATE: DATE:

Drawing No.: Drawing No.: Sheet of

Issue level date: Issue level/date: o 1.1 Geometry, Dimensional testing o 1.9 ESD Test
o 1.2 Functional Test o 1.10 Reliability Test
King. Requirements Measured data Specifi cation Comments; o 1.3 Test Materials or 2 Sample / Pattern
c o 1.4 Perception test (appearance, touch) or 3 Technical specifications
ied? o 1.5 Acoustic Test or 4 AMFE Product
No. Specifications (supplier) satis No o 1.6 Odor Test o 5 Design approval
Forks
□ □ o
o
1.7 Visual appearance test
1.8 Surface Test
o 6 Compliance with Legal Requirements
o 7 IMDS / Material Data Sheet
□ □ Supplier / Production Plant: Customer
□ □ ID No./ DUNS Code: ID No:
Report No.: Index Report No.: Index
□ □ Denomination Denomination
□ □ Client Reference Client Reference

□ □ Plan No.:
State: Date:
Plan No.:
State: Date:
□ □

2
3
COMPARISON OF PPAP WITH
VDA2 Ref.
Requirements Specifications
Real Value
Fulfille and
d ficacio Observations:

VDA 2 PPA: Detailed presentation report

No.: Supplier Speci No:
Yes
eithe eithe
r
eithe reithe
r reithe

Documents related to the process and other

eithe
r reithe
eithe
r reithe
eithe
r eithe
r

documents.
eithe
r reithe
eithe
10 Process Flow Diagram
Process-related and other documents issue:____/ Date: r reithe State:
eithe Date:
r eithe
r
eithe Sheet of
Sheet of....... r reithe
8eithe
Software Testing o 16 Utility Status Report
r reithe
eithe
o 9eithe
AMFE
r reithe Process o 17 Evidence of Agreed Capacity
r reithe
ox 10
eithe
Process Flow Diagram
r reithe o 18 Self-control instruction
eithe
o 11 r reithe
eithe
Product Control Plan
o 19 History of the Piece

□ 89 Software test report

Process FMEA
• 16 Tooling list
17 Confirmation of agreed capacity o 12 r Process
eithe r
eithe Capability Testing
o 20 Transportation Aptitude Test Incl. storage
□ D r eithe
eithe r

□ 10 Process flow chart

□ 18 Written self-assessment o 13 Special Features Control
r eithe
eithe r o
21 PPF Supply Chain Status
11 Control plan 19 Part history
□ □ o 14 r List
eithe r of Control Media
eithe
o
22 Release of Laminating Systems
12 Confirmation of process capability 20 Confirmation of suitability of transport
□ □ Supplier
equipmentConfirmation
r r
15 Test Equipment Capacity
Customer decision: o
23 Others
Observations Approved either
13 Achievement of special characteristics 21 PPA status of the supply chain
□ □ Rejection, new sample
Supplier presentation required
/ Production Plant: either Customer
Observations:
□ 14 Test'inspection equipment list □ 22 Approval for coating systems ID No./ DUNS Code: ID No:
15 Capability study testing equipment 23 Others
□ □ Report No.: Index Report No.: Index
Denomination Denomination
Supplier/production location: Customer:
Client Reference Client Reference
ID No. t DUNS code: ID No.:.:
Name NamePlan No.: Plan No.:
Report No.: Index: ReportDepartment
No.: Index: w boccnetodw czomg I Department
Description: Description:
Phone PhoneState: Date: State: Date:
Part No.: Fax:
Part No.: - Fax: -
E-mail: E-mail:
Drawing No.; Drawing No.:
Issue level/date: Supplier Confirmation Remarks Customer decision:
Issue Date:
level/date: Signature: Date: Signature:
Approved either
Confirmation by supplier:
Decision by customer;
Rejection, new sample presentation required either
Comments: Observations:
Released
□
Rejected; reapproval of PPA
Process is required
n
Comments:

Name Name

Yam: Yam. Department: Department :

Dept. Dept: Phone Phone
Telephone Telephone
Park Fax; Fax: - Fax: -
E-mail: I -mail:
E-mail: E-mail:
Fact.___________Signed:_______________ Date:______________Signed:__________________

Date: Signature: Date:

Signature:

2
4
COMPARISON OF PPAP WITH
VDA2

2
5
 OTHER ISSUES TO CONSIDER IN A PROJECT

Other issues to consider in a project

Escalation Process: Project Deviation
Change control
Project documentation
Special Features
Table of special characteristics equivalences
Product safety
Control and archiving Engineering specifications
Legal Regulations
Backup or substitute controls
Controls Error Detection

2
6
Audit, Consulting and Training
 Thank you
Thank you
Thank

youMerciDankeschön 謝
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