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APQP Kickoff Meeting

This document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

Part number(s): Part Description: Supplier Name:


X

Date: Supplier Code: Supplier Location:

SECTION 1 - CUSTOMER REQUIREMENTS 1.1


Yes No Does the Supplier understand all the applications and intended end uses of the parts/materials for all customers?

Explain: 1.2
Yes No Does the Supplier have the latest information about program timing (examples include Drawing release, Prototype, PPAP date, Build date, Material required at plant date, Start of Production, Volumes)?

Explain:
Review Key Project Milestones with Supplier:
Key Project Milestone Date Key Project Milestone Date

1.3

Yes

No

Does the Supplier have copies of the latest versions of and understand the ISO 9001 and, if applicable, ISO/TS 16949 quality management standards, the AIAG manuals (APQP, PPAP,FMEA, SPC, MSA) and, where appropriate, the AIAG CQI special process manuals?

Explain: 1.4
Yes No Does the Supplier have and understand all the requirements listed in the Navistar Integrated Supplier Quality Requirements, Navistar forms, and other Navistar requirements (e.g. appearance item approval and CEMS B-50)

Explain: 1.5
Yes No Does the Supplier understand the requirements of Navistar Packaging Specification D-13?

Explain: 1.6
Yes No Are returnable containers required?

Explain: 1.7
Yes No Are there any packaging issues left to resolve (such as alternative packaging, dunnage, protective sleeves)?

Explain: 1.8
Yes No Is the Supplier ready to receive Navistar EDI orders?

Explain: SECTION 2 - PRODUCT DESIGN / DEVELOPMENT 2.1


Yes No Does the Supplier have and understand ALL of the latest drawings and specifications, including CEMS B-50?

Explain: 2.2
Yes No If Navistar is design responsible, has a Design-FMEA review been completed with the Supplier and the Navistar Engineer and records of review are available?

Explain:

APQP Kickoff Meeting


This document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

Part number(s): Part Description: Supplier Name:


X

Date: Supplier Code: Supplier Location:

2.3

Yes

No

If Navistar is design responsible, have YC, YSs from the DFMEA been analyzed, and decisions made to include in PFMEA & Control Plan? Is the Supplier aware AIAG FMEA Manual? Is the Suppliers intended process able to meet the capability requirements of the CCs, SCs?

Explain: 2.4
Yes No If Supplier is design responsible, has a Design-FMEA been updated as necessary? Are actions in place to reduce high RPNs? Have the updates been reviewed with the Navistar Engineer?

Explain:
If Supplier is design responsible, has the IQA (Installation Quality Assurance) been submitted to and approved by Navistar R&Q? IQA applies to No Vehicle systems (Brakes, Transmission, Engine, Steering, Radiators, Fan Drivers, SCR, Batteries) and Engine Systems (Fuel, EGR Valve, EGR Cooler, Turbo, Intake Throttle, Damper, Flywheel).

2.5

Yes

Explain: 2.6
Yes No Are there any Pre-Prototype/Prototype requirements?

Explain:
List them below: Prototype Material Required Date Quantity Supplier Promise Date

2.7

Yes

No

Does the Supplier understand the requirements of the Navistar procedure (with Phased PPAP) for prototype parts and the requirement that prototype parts must be inspected, verified and validated that they meet design intent?

Explain: 2.8
Yes No Will the appropriate control plan be developed for use during each build (e.g. NPD build events, Prototype, Pre-Launch, and Production)?

Explain: SECTION 3 - PROCESS DESIGN/DEVELOPMENT


Key Activities from the APQP Project Plan

3.1

Yes

No Has the Supplier filled out, updated and submitted the Navistar APQP workbook for these parts?

Explain: 3.2
Yes No Has the Supplier completed APQP plan entries into the Navistar New Part Tracking (NPT) System, if applicable?

Explain: 3.3
Yes No Has error proofing been considered during PFMEA development and included in quoted price?

Explain: 3.4
Yes No Are any new equipment, tooling, gages, special fixtures or test equipment needed to produce this part?

Explain:

APQP Kickoff Meeting


This document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

Part number(s): Part Description: Supplier Name:


X

Date: Supplier Code: Supplier Location:

3.5

Yes

No

Navistar's minimum required acceptance criteria for the PPAP initial study is a Cpk or Ppk of 1.67 (ref. AIAG PPAP manual). Are any print, material specifications or process control plan changes needed to meet these requirements?

Explain: 3.6
Yes No Has the Supplier confirmed that their subcontractors will do the following?: APQP

Explain: 3.7
Yes No Has the Supplier confirmed that their subcontractors will do the following?: PPAP

Explain: 3.8 Enter lead time for tooling (wks): 3.9 Enter date for first production run & submission of PPAP: 3.10 Enter estimated PPAP Submission Date: 3.11 Submission Level (1- 5) 3.12 Enter number of Cavities / Molds to submit for PPAP: 3.13 Enter number of Cavities / Molds to submit for PPAP: 3.14
Enter number of parts per Cavity / Mold in PPAP production run:

3.15 Enter the name of the person you will submit PPAP to: EARLY PRODUCTION CONTAINMENT

3.16

Yes

No Does the Supplier understand that the Pre-Production Control Plan (with extra tests, examinations will remain in place until Job-1 plus 90 Days)?

Explain: 3.17
Yes No Does the Supplier understand that the exit strategy to return to the normal Control Plan is: no defects during the first 90 days; 1.67 Cpk for CC's and SC's at PPAP and 1.33 Ppk for each of the first three months of production?

Explain: SECTION 4 - RUN @ RATE & CAPACITY RELATED 4.1


A. Daily Contracted Capacity B. Number of tool sets required C. Number of machines/lines/cells required D. Capacity per tool set E. Number of work hours per day F. Number of shifts per day G. Number of days per week

4.2

Yes

No Does the Supplier understand the Navistar Capacity Planning Verification process?

Explain: 4.3
Yes No Does the Supplier understand that Navistar pays for tooling only upon successful completion of PPAP with Capacity Verification that verifies the Supplier can meet the daily contracted capacity?

Explain: SECTION 5 SUPPLIER QUALITY PERFORMANCE 5.1


Yes No Does the Supplier understand the Navistar Global 8D requirements and are there any unresolved Global 8Ds?

Explain:
Does Supplier understand the requirements for controlled shipping level 1 and 2 and Navistar Quality Top Focus program? Are any parts currently on controlled shipping status?

5.2

Yes

No

Explain: 5.3
Yes No Does the Supplier understand the Navistar Change Management requirements, Supplier Request for Change Authoprization (SRCA), and the Deviation process?

APQP Kickoff Meeting


This document should be completed by the Supplier and provided to the SQE/SDM prior to the meeting date.

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

Part number(s): Part Description: Supplier Name:

Date: Supplier Code: Supplier Location: X Does the Supplier understand the Navistar Change Management requirements, Supplier Request for Change Authoprization (SRCA), and the Deviation process?

5.3

Yes

No

Explain: 5.4
Yes No Has an NSA (Navistar Supplier Assessment) been completed? If so, what was the score and classification? Are the corrective actions from the NSA closed?

Explain: 5.5 Explain:


Navistar Attendees: Date: Supplier Attendees: What is the Suppliers current R/1000 or PPM for current customers with similar products: PPM R/1000

Advanced Supplier Quality Engineer

Plant Quality Manager

Product/Design Release Engineer Supply Manager Materials Representative

Quality Manager Program Manager Manufacturing Engineer

Quality Engineer

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

e Supplier and provided to the SQE/SDM prior to the meeting date.

CUSTOMER REQUIREMENTS

and intended end uses of the parts/materials for all customers?

t program timing (examples include Drawing release, Prototype, PPAP date, Build date, Material s)?

ns of and understand the ISO 9001 and, if applicable, ISO/TS 16949 quality management A, SPC, MSA) and, where appropriate, the AIAG CQI special process manuals?

uirements listed in the Navistar Integrated Supplier Quality Requirements, Navistar forms, and approval and CEMS B-50)

Navistar Packaging Specification D-13?

h as alternative packaging, dunnage, protective sleeves)?

s?

ODUCT DESIGN / DEVELOPMENT


latest drawings and specifications, including CEMS B-50?

EA review been completed with the Supplier and the Navistar Engineer and records of review are

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

e Supplier and provided to the SQE/SDM prior to the meeting date.

om the DFMEA been analyzed, and decisions made to include in PFMEA & Control Plan? Is the iers intended process able to meet the capability requirements of the CCs, SCs?

EA been updated as necessary? Are actions in place to reduce high RPNs? Have the updates

allation Quality Assurance) been submitted to and approved by Navistar R&Q? IQA applies to teering, Radiators, Fan Drivers, SCR, Batteries) and Engine Systems (Fuel, EGR Valve, EGR

ts?

the Navistar procedure (with Phased PPAP) for prototype parts and the requirement that idated that they meet design intent?

use during each build (e.g. NPD build events, Prototype, Pre-Launch, and Production)?

OCESS DESIGN/DEVELOPMENT

the Navistar APQP workbook for these parts?

o the Navistar New Part Tracking (NPT) System, if applicable?

A development and included in quoted price?

ures or test equipment needed to produce this part?

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

e Supplier and provided to the SQE/SDM prior to the meeting date.

or the PPAP initial study is a Cpk or Ppk of 1.67 (ref. AIAG PPAP manual). Are any print, material ded to meet these requirements?

rs will do the following?: APQP

rs will do the following?: PPAP

ODUCTION CONTAINMENT

ion Control Plan (with extra tests, examinations will remain in place until Job-1 plus 90 Days)?

to return to the normal Control Plan is: no defects during the first 90 days; 1.67 Cpk for CC's and ee months of production?

N @ RATE & CAPACITY RELATED

ty Planning Verification process?

or tooling only upon successful completion of PPAP with Capacity Verification that verifies the

PPLIER QUALITY PERFORMANCE

8D requirements and are there any unresolved Global 8Ds?

ntrolled shipping level 1 and 2 and Navistar Quality Top Focus program? Are any parts currently

e Management requirements, Supplier Request for Change Authoprization (SRCA), and the

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

e Supplier and provided to the SQE/SDM prior to the meeting date.

e Management requirements, Supplier Request for Change Authoprization (SRCA), and the

completed? If so, what was the score and classification? Are the corrective actions from the NSA

R/1000

Navistar Advanced Product Quality Planning - Worksheet and Report


Customer: Supplier Name: Supplier Team Members Responsibility

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Report Date: Part Number: 3/11/2014

Navistar Inc.

Program: Part Name: Entering the Team

Date for the Team Leaving the Team

Email / Phone

Customer Contact Names

Responsibility

Entering the Team

Leaving the Team

Email / Phone

APQP Element
Current

GYR Status Last Trend

Program Need Date

Planned Date

Closed Date

Resp. Initials

Remarks

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

Design Review Drawings and Specifications Preliminary Bill of Materials Design Failure Mode Analysis (DFMEA) Design Verification Requirements Design DVP&R Design Verification Test Review Preliminary Process Flow Diagram Utilities Plan, Layout Plan & Manpower Plan Capital Equipment Plan Tooling Measure and Test Equipment Prototype Process Flow Diagram Prototype Process Failure Mode Analysis (PFMEA) Prototype Build Control Plan Operator Inspection and Process Instructions Logistics (Internal and External) Packaging (Internal and External) Safety & Environment Pre-Production Process Flow Diagram Pre-Production Process Failure Mode Analysis Pre-Production Control Plan Preliminary Capability Studies Production Test and Measuring Equipment Planned Maintenance and Key Spares Requirement Production Readiness Review Process Capacity Sign-off Product and Process Validation (Phase-1 Parts) Product and Process Sign-off (Phase-2 Parts) Sub-Supplier Direct Materials / Prototypes Sub-Supplier Tooling and Equipment


Program Manager Quality Representative Customer Representative Date Date Date

Program Milestones Must Be On Timing Plan

Approvals :

Design
If NOT APPLICABLE Element is left blank Project Element 1) 1.1 1.2 1.3 1.4 1.5 2) Key Requirements Design Review Does the documentation show that all design changes are approved by the customer? Have all design changes been incorporated into the latest specifications and drawings? Do design changes have an impact on the timing plan and the customer Material Required Dates? Do design changes have an impact on the time and costing of manufacturing run at rates? Have design reviews been conducted with manufacturing? Drawings and Specifications (received from Navistar) 2.1.1 2.1.2 2.1.3 Is a complete set of drawings (schematic, mechanical, layout) available and released for the latest level product? Does the supplier have the latest specification and test requirements? Where appropriate, have these been flowed down to the sub-suppliers? Have 'Significant Characteristics' and Pass Through Characteristics been agreed to? Manufacturing 2.2.1 2.2.2 2.2.3 2.2.4 3) 3.1 3.2 3.3 3.4 4) 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5) 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 Has the Feasibility Commitment been completed and signed as evidence of that the product can be produced? Have current manufacturing drawings been issued internally / Subsupplier plant? Have all specifications and drawings been agreed by the manufacturing source? Have all dimensions that affect fit, function and durability been identified, and are they fully understood, and agreed? Preliminary Bill of Materials Is the Bill of Materials complete and costed, Does it meet the business target? Are component standards defined? Is the BOM full volume capable? Is the BOM available and released? DFMEA Has the initial DFMEA been compiled. Are the functions needed reviewed by a Cross-Functional team? Have Customer Significant Characteristics / Key Characteristics been identified? Has historical product and warranty data been considered. Have failures at Concept Verification / Design Verification testing been considered? Are risks identified for meeting durability and reliability goals. Where identified are plans in place to reduce risks? Have high RPN's been addressed, corrective actions defined, reviewed and verified? Is there a pareto of high RPN's available? Has the DFMEA been reviewed after design and / drawing revisions? Is the DFMEA in-line with drawing revisions? Has the customer reviewed the current DFMEA? Design Verification Requirements Is the design in accordance with the functional requirements? Is a complete set of drawings (schematic, mechanical, layout) available? Are there any further design changes planned? Is the design FMEA in line with the drawing revision? Are there any unproven new technologies or design features? Are there any new manufacturing processes required? Has assembly build variation been reviewed and considered? Are any new materials used in the design? Is any new special tooling required for the design? Has the DV test plan been worked out? have special characteristics been identified? Status GYR Current Last Comments

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Target Date Resp. for Initials Completion Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Design
If NOT APPLICABLE Element is left blank Project Element 5.12 5.13 6) 6.1 6.2 6.3 6.4 7) 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 Key Requirements Are the manufacturer and test of prototypes identified? Are the sample requirements understood for timing and quantity? Design DVP&R Does the DV test plan meet the customer requirements? Has DV testing passed successfully? Do the DV results meet the customer specification requirements? Are failed items during production validation testing covered by corrective actions (8D); are corrective actions verified and retested? Design Verification Test Review Are there any significant design changes from test level (drawings and specifications)? Are the drawings / specifications / BOM released? Is the Design FMEA in line with the drawing revision? Are test parts representative of a production source? Have all specifications and drawings been agreed by the production source? Are the chosen designs and processes capable of mass production? Have high RPN's at the Design FMEA from the CV review been resolved? Have any new high RPN's shown up during the CV level phase? Are risks identified (function, manufacturing, durability, timing, costs)? Is the Design now frozen or are further tests required? Status GYR Current Last Comments

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Target Date Resp. for Initials Completion

Element Responsibility:

Element Responsibility:

Plant + Process
If NOT APPLICABLE Element is left blank Project Element 8) 8.1 Key Requirements Preliminary Process Flow Diagram Does the flow chart show all operations, control points from receiving to shipping; Is the planned manufacturing flow adequate and without major risk? Are critical processes, control points for customer designated characteristics and / or critical processes / product characteristics included and highlighted? Utilities Plan, Layout Plan & Manpower Plan Does the floor plan have clearly marked areas for all materials, tools, and equipment at each operation? Has sufficient space been allocated for all equipment? Will there be adequate services (e.g. electricity, compressed air) available on time? Have controls been established to eliminate the potential for an operation, including outside processing, to contaminate or mix similar products? Is material protected from overhead or air handling systems contamination? Are inspection points logically located; adequate for staging and hold areas? Is there a recruitment and training plan that meets the needs of ramp-up, and production processes at full 'run at rate' that includes quality inspection and maintenance support? Is there a training matrix by employee skill level showing numbers and training required? Capital Equipment Plan Is the timing plan for new manufacturing equipment developed, reviewed and monitored? Does the procurement and installation meet the customer timing requirements? Have purchase orders been approved and released? Are run off with intended production rates scheduled and carried out at equipment suppliers. Results meet capacity and quality targets? Does run off at manufacturing installation meet the process parameters as defined at production rates scheduled? Have capability studies been scheduled and carried out at manufacturing site, measurements done in representative quantities, with results that meet the customer requirements? Tooling Is the timing plan for new tooling developed, reviewed and monitored? Does the procurement and installation meet the customer timing requirements? Have purchase orders been approved and released? Does timing include try out and optimization? Have capability studies been scheduled and carried out at manufacturing site, measurements done in representative quantities, with results that meet the customer requirements? Is try out and optimization complete? Measuring and Test Equipment Is all measuring and test equipment identified, is it included in the timing plan? Have all test and measurement equipment requirements been defined and communicated to suppliers? Is the procurement and installation of measurement equipment on time? Are measurement system studies planned, conducted and approved (MSA R&R..)? Are MSA results acceptable? Have detailed test / inspection operator instructions in place. Have provisions been made to certify and routinely calibrate measurement and test equipment? Prototype Process Flow Chart Does the flow chart show all operation, control points from incoming goods to dispatch; Is the planned manufacturing flow adequate and without major risk? Are critical processes, control points for customer designated characteristics and / or critical processes / product characteristics included and highlighted? Status GYR Current Last Comments

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Target Date Resp. for Initials Completion Element Responsibility:

8.2

9) 9.1 9.2 9.3 9.4 9.5 9.6 9.7

Element Responsibility:

9.8

10) 10.1 10.2 10.3 10.4 10.5 10.6

Element Responsibility:

11) 11.1 11.2 11.3 11.4 11.5 11.6 12) 12.1 12.2 12.3 12.4 12.5 12.6 12.7

Element Responsibility:

Element Responsibility:

13) 13.1

Element Responsibility:

13.2

Plant + Process
If NOT APPLICABLE Element is left blank Project Element 14) 14.1 14.2 14.3 14.4 15) 15.1 15.2 15.3 15.4 16) 16.1 16.2 16.3 16.4 16.5 17) 17.1 17.2 17.3 17.3 17.4 18) 18.1 18.2 18.3 19) 19.1 19.2 20) 20.1 Key Requirements Prototype Process FMEA Is the Process FMEA started, are the functions needed part of the FMEA team Is a pareto available of high RPN's. Is the severity ranking consistent with the DFMEA and the customer significant characteristics? Have corrective actions been defined, reviewed and verified? Does the match the Process Flow? Prototype Control Plan Does the control plan include the customer significant characteristics? Does the control plan match the Process Flow and PFMEA Are sample sizes for dimensional measurements, material and functional tests adequate for prototype builds? Does the control plan address incoming (material / components) through processing / assembly including packaging? Operator Inspection / Process Instructions Are work instructions complete and released? Are instructions available on how to proceed with non-conforming material; i.e. Analysis, rework, disposition of NC material / returned material? Are instructions available for machine / job set-ups? Are inspection instructions available that define checking frequencies, sample sizes, acceptance standards and test specifications? Are methods and facilities available for recording inspection / test results? Logistics Internal / External Is the customers schedule known and understood? Does the delivery frequency agree with the customer RFQ? Has a transport provider been agreed? If required; Has a Logistics FMEA been completed, and updated? Has internal transport, WIP controls, storage space, etc. been defined? Packaging Internal / External Has a packaging and logistics trial been scheduled to assess risk for handling, cleanliness, damage, identification and procurement costs? Will sufficient packaging be available for a significant production run and support full volume production? Has a packaging / labeling specification been raised, agreed and released by the Customer? Safety and Environment Are there any customer or regulatory requirements for the notification of hazardous substances e.g. MSDS and IMDS requirements? Has Navistar CEMS B-50 been taken into account during product and process design? Pre-Production Process Flow Diagram Does the flow chart show all operation, control points from incoming goods to dispatch; Is the planned manufacturing flow adequate and without major risk? Are additional checks in place for pre-launch activities for critical processes, control points for customer designated characteristics and / or critical processes / product characteristics included and highlighted? Is there a manufacturing floor plan showing where the equipment, material flow is located in the manufacturing site? Pre-Production Process Failure Mode Analysis Does the PFMEA track the Production Flow diagram to support additional inspection and test during launch? Is a pareto available of high RPN's. Is the severity ranking consistent with the DFMEA and the customer significant characteristics? Have corrective actions been defined, reviewed and verified? Are 8D activities that have resulted from CV and DV testing been captured on the PFMEA. Have the corrective actions been verified, validated and RPN's re-scored? Status GYR Current Last Comments

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Target Date Resp. for Initials Completion Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

20.2 20.3 21) 21.1 21.2 21.3 21.4

Element Responsibility:

Plant + Process
If NOT APPLICABLE Element is left blank Project Element 22) 22.1 22.2 22.3 23) 23.1 23.2 24) 24.1 24.2 24.3 24.4 24.5 24.6 24.7 25) 25.1 25.2 25.3 26) 26.1 26.2 26.3 26.4 26.5 26.6 26.7 26.8 26.9 26.10 27) 27.1 27.2 28) 28.1 28.2 28.3 Key Requirements Pre-Production Control Plan Does the pre-launch Control Plan include additional activities such as increased inspection, in-process and final check points? Are these addition pre-launch controls monitored by SPC or 100% inspection for customer Significant Characteristics and Key Production characteristics? Does the Control Plan track the process steps in the Process Flow chart and the PFMEA? Preliminary Capability Studies Have short term studies been carried out that provide statistical data to show process capability. Have preliminary process capability studies been performed on the characteristics identified in the Control Plan. Production Test and Measuring Equipment Has test and measuring equipment been identified, is it included in the timing plan and progress being monitored? Have all test and measurement requirements been defined and communicated to the suppliers? Is procurement and installation of test and measurement equipment on time? Are detailed test and inspection operator instruction available on the manufacturing site, are the operators trained in the use of instructions and recording methods? Have provisions been made to certify and routinely calibrate measure and test equipment? Has Measurement System Analysis been carried out on all inspection and test equipment on the control plan to evaluate product? Where MSA results are not acceptable is there a corrective action plan in place to meet compliance? Planned Maintenance and Key Spares Requirement Has all production equipment and tooling been included in the PM program? Have all key spares been identified that ensure production is optimized to prevent show stoppers? Are manning and necessary trained personnel available to maintain volume production? Production Readiness Review Has all Design Validation passed testing and been approved by the customer? Are all Design Validation documentation complete and DV issues / 8D's closed with countermeasures in place? Have all component and assembly drawings been updated and released? Are customer specification complete (software and function) and requirements frozen? Has all production documentation been completed and released to manufacturing? Has the Production trial run been scheduled with adequate quantity of parts that represents Production Rates Has the Process Flow / PFMEA and Control Plans been completed, reviewed and approved? Are all necessary inspection gages job set-ups and operator instructions in place to support production? Are product control points in place including identification of nonconforming and reworked product? Are all production processes been production tooled? Process Capacity Sign-off Can customers peak planned capacity be achieved at representative production runs and at costed rates? Has forecasted capacity verification been submitted to the customer buyer? Product and Process Validation (Phase-1 Parts) Is a Production validation (PV) plan established? Are PV tests complete and approved? Are failed items covered by corrective actions (8D); corrective action verified and re-tested? Status GYR Current Last Comments

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Target Date Resp. for Initials Completion Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Element Responsibility:

Plant + Process
If NOT APPLICABLE Element is left blank Project Element 29) 29.1 29.2 29.3 Key Requirements Product and Process Sign-off (Phase-2 Parts) Are all activities on time to achieve Parts Submission Warrant (PSW) Is all Production Parts Approval Process (PPAP) documentation complete and readily available? Has the customer signed the PSW authorizing shipment? Status GYR Current Last Comments

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Target Date Resp. for Initials Completion Element Responsibility:

Sub-Supplier
If NOT APPLICABLE Element is left blank Project Element 30) 30.1.1 30.1.2 30.1.3 30.1.4 30.1.5 Key Requirements Sub-Supplier Selection - Direct Materials Has a Sub-supplier been selected, are parts identified? Have long lead and high risk suppliers been identified, has a plan to manage them been developed? Have all specifications and drawings been raised, completed and released? Is there a matrix of all purchased in assemblies / components and is this reviewed? Were applicable, are suppliers APQP / PPAP status to plan? Sub Supplier Selection - Prototypes 30.2.1 30.2.2 30.2.3 30.2.4 30.2.5 30.2.6 Has a Sub-supplier been selected, to build outsourced Prototype Parts? Have current manufacturing drawings been issued internally and Subsupplier plant? Have all specifications and drawings been agreed by the prototype manufacturing source? If testing of prototypes is outsourced, does the supplier fully understand and agree the DVP&R requirements? Have all dimensions that affect fit, and function been identified, and are they fully understood, and agreed? Has a manufacturing feasibility commitment been agreed that the Prototype design can be manufactured, assembled, meet required material dates and quantities? Sub-Supplier - Capital Equipment Is a capital equipment timing plan developed, monitored? Have capital equipment suppliers been identified and documented? Have long lead and high risk suppliers been identified, has a plan to manage them been developed? Have capital equipment specifications (including capability requirements) been raised and released? Are try-out schedules at supplier / manufacturing site agreed and understood. Where applicable, are suppliers APQP status to plan? Sub Supplier - Tooling 31.2.1 31.2.2 31.2.3 31.2.4 31.2.5 Has a tooling timing plan been developed, monitored? Have tooling suppliers been identified and documented? Have long lead and high risk suppliers been identified, has a plan to manage them been developed? Have tooling equipment specifications (including capability requirements) been raised and released? Where applicable, are suppliers APQP status to plan? Status GYR Current Last Comments

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision Target Date Resp. for Initials Completion Element Responsibility:

31) 31.1.1 31.1.2 31.1.3 31.1.4 31.1.5 31.1.6

Element Responsibility:

EARLY PRODUCTION CAPABILITY

ISQ-005-FO Rev: B Date: 03/08/2013 Copies must be verified for latest revision

Supplier -- Cpk Values


Submission Date:

Supplier:
Part number: Rev. Level: Test Method/ Measuring Equipment

Special Characteristics Tolerance/ Sketch

Test/ Sample Gage R&R Size e

Ppk - Chart
Ppk -- Values
5

Jan Max Ppk Min Ppk Target

Feb

Mar

Apr

May Jun

Jul

Aug Sep

Oct

Nov

Dec

4
3 2

1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33

1
0

Ppk -- Values 5 4 3
2 1 0

Jan Max Ppk Min Ppk Target 1.33

Feb

Mar

Apr

May Jun

Jul

Aug Sep

Oct

Nov

Dec

1.3 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33

Ppk -- Values 5 4

Jan Max Ppk Min Ppk Target

Feb

Mar

Apr

May Jun

Jul

Aug Sep

Oct

Nov

Dec

3 2 1 0

1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33

Ppk -- Values
5 4 3 2

Jan Max Ppk Min Ppk Target

Feb

Mar

Apr

May Jun

Jul

Aug Sep

Oct

Nov

Dec

1 0

1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33

Ppk -- Values 5

4 3 2 1
0

Jan Max Ppk Min Ppk Target

Feb

Mar

Apr

May Jun

Jul

Aug Sep

Oct

Nov

Dec

1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33

Ppk -- Values
5 4 3 2

Jan Max Ppk Min Ppk Target

Feb

Mar

Apr

May Jun

Jul

Aug Sep

Oct

Nov

Dec

1 0

1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33 1.33

Rev. No. A

Effective Date 11/1/2012

3/8/2013

Revision History New form ISQ-005-FO for ISQ (KdW, 10/19/2012) Fixed functionality issues related to form function. Changed checkboxes to individual cells. Removed the shading. Removed PTC Analysis From and Capacity Verification Forms.

ISQ-005-FO

Rev: A Copies must be verified for current revision.

Date: 11/01/2012

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