APQP FOLLOW-UP MATRIX

Plant: Date:
CUSTOMER MODEL YEAR PROGRAM TASK Supplier Program Contact List of Key Contacts for Customer 1 APQP Kick-off / Sourcing Decision Review of APQP Timing with Launch Team Responsible and dates assigned Master copy signed by the LQE 2 Team Feasibility Commitment Feasibility Analysis Open Issues List Issues Closed Process Flow Chart and Manufacturing Floor Plan Processing Methods Equipment Number of Operators per Station Inspection Stages Manufacturing Floor Plan Repair/Rework areas Finished Product areas Lighting at each station 4 Nonconforming material area Design FMEA Potential Failures Documented Rank Potential Failures Document Corrective Actions 5 Signed off review. Design Review Design Review Report Open Issues List 6 Issues Closed Value Engineering Establish VA/VE Team 7 Schedule Meetings Subcontractor APQP Assessment Review of Sub-suppliers APQP package Open Issues List 8 Issues Closed Process FMEA Establish FMEA Team Potential Failures Documented Rank Potential Failures Document Corrective Actions 9 Design Verification Plan and Report (DVP&R) R 3/8/00 ` ISSUE / FACTS G ACTIONS / COMMENTS PPAP SOP WBP -5228
PHASE #

RESPONSIBLE

DUE

COMPLETE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87

DVP&R Summary Available 10 Tool Design and Approval Design Tool Review Open Issues List Design Tool Approval 11 Appearance Approval Plan AAR complete and submitted AAR approved by Customer 12 Prototype & Production Tool Build Tool Build Schedule Open Issues List Issues Closed Tools Identified (JCI Property Tag) List of Tools with current Eng. Levels 13 Gage Design and Approval Calibration plans Maintenance Plans Gage Purchase Approval 14 Gage Build, Certification, and R&R Gage Build Schedule Gage R & R (=<20%) Open Issues List Issues Closed Gages Identified (JCI Property Tag) List of Gages (numbered, Eng. Level and calibration date) Calibration Test procedures 15 Prototype Build Control Plan Prototype Control Plan Data collecting and analyzing system 16 Prototype Builds Review Team Capability studies for SC's Process Flow Diagram Revised DFMEA Revised PFMEA Revised Control Plan Revised Prototype assembly evaluation report 17 Prototype PPAP (if req'd) Warrant labeled as Prototype PPAP Package 18 Drawings and Specifications Review Identify Critical, significant and customer designated characteristics for the product and subcomponents Establish measurement technique 19 Error and Mistake Proofing Identify potential process/design faults
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APQP FOLLOW-UP MATRIX

Plant: Date:
CUSTOMER MODEL YEAR PROGRAM TASK 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 32 List of Pokeyoke systems Open Issues List Issues Closed 20 Equipment Design and Approval New equipment needs defined New equipment Build Schedule 21 Packaging Specifications Define Packaging Specifications Prove-out Packaging Design Obtain Approval for Packaging Obtain Approval for Method of Transportation Labels meeting AIAG requirements 22 Tool Qualification Dimensional Inspection Report Capability study report 23 Material Certification / Material Testing Material Test Results Lab accreditation 24 Preventative Maintenance Plan Preventative Maintenance Schedule P.M. Instructions P.M. Training Identified tooling for each machine Calibration procedure followed. 25 Pre-Launch Control Plan 26 Equipment and Fixture Build Equipment/Tooling List and Timing Engineering and Quality Issues addressed Equipment / Tooling Cost Equipment / Tooling authorization 27 Operator Instructions Operator Process instructions Rework/Repair Instructions Instructions to current revision levels Operator Instructions tied to Control Plan Start up checklist Visual aides included in the instructions 28 Production Control Plan 29 Containment Plan (Incoming & Outgoing) Documented Incoming Requirements Documented Finished Part Audit Suppliers on approved supplier list Current specs on all material identified Subsupplier PPAP's Boundary Samples Lot Traceability 30 Problem Solving Methods 8D's for problems during Launch 8D's closed before Launch SPC setup 31 Production Trial run Done by trained production operators Open Issues List Line Balance Material Handling Systems Manufacturing Process Assessments Preliminary (Short Term) Process Capability Study Special Causes Identified 3/8/00 ` ISSUE / FACTS ACTIONS / COMMENTS PPAP SOP WBP -5228
PHASE #

RESPONSIBLE

DUE

COMPLETE

Cpk >= 1.67 Cp>=2.0 33 Dimensional Studies Dimensional Results Report Master Samples 34 PSO: Documentation Review Open Issues List Issues Closed 35 PSO: Process review & Run-at-Rate Run-at-Rates established Production Operators Identified Production Rates demonstrated Staffing Plan for +/- 10% production fluctuation Machine Capability Study Plan for projected ramp-up and peak demands Top 3 bottlenecks identified with action Capacity analysis versus demand Contingency plan established in case of equipment breakdown Statistical process capability on critical dimensions Conformance to every item in control Plan 36 Product Validation Testing Product Performance Specifications PV Test Plan Test samples from production run PV Test Results Reports Open Issues List Issues Closed 37 PPAP Complete PPAP Package complete (level 3) 38 Master Samples Master Samples List
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APQP FOLLOW-UP MATRIX

Plant: Date:
CUSTOMER MODEL YEAR PROGRAM TASK 176 177 178 179 180 181 182 183 184 185 R Y G N/A A B C Master Samples Identified Record Retention 39 Production Part Delivery EDI/ASN systems in place Backup transmission sources P.O. numbers and pricing verified Shipping Labels verified PPAP Approval 40 Lessons Learned Meeting Scheduled. RED - Will negatively impact schedule, cost or performance (Task late >= 4 weeks) YELLOW - Could negatively impact schedule, cost or performance (Task late <= 4 weeks) GREEN - On schedule or complete (Task done or on-time) NO COLOR - Task not due to begin N/A - Not applicable to this program Program Scope: Major Program Scope: Medium Program Scope: Minor 3/8/00 ` ISSUE / FACTS ACTIONS / COMMENTS PPAP SOP WBP -5228
PHASE #

RESPONSIBLE

DUE

COMPLETE

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