Advanced Product Quality Planning (APQP) is a structured method for determining and performing the actions essential to ensure something satisfies the customer along with cost and time. APQP is necessary of all vehicle, system, subsystem and part manufacturing locations.
1. 2 Goal
The goal of APQP is to assist in communication with all individuals involved with a program and ensure that required steps are completed on time, at satisfactory cost and quality levels.
1. 3 Purpose
The purpose of this guide is to determine:
Common APQP anticipations for those M&M activities.
Common APQP process metrics.
Common APQP deliverables.
A common program status-reporting format.
Lead and Support assignments and responsibilities for each APQP Aspect.
1. 4 Approach
APQP emphasise on Up-front planning, First three part of the P-D-C-A circuit are devoted to up-front product quality planning through product / Process Validation. The Action of implementation, the fourth part is the point where the importance of evaluating the output assists two functions; to determine if customers are satisfied, and also to support the quest for continuous improvement.
This guideline focuses on 23 key APQP elements. Explanations, prospects, and deliverables for these elements are determined in Section 5. 0 APQP Factor Description of this guideline. The status for these disciplines is summarized on the APQP Status Report. This guide provides a management tool for follow-up and well-timed completion of most 23 APQP Elements.
1. 5 Applicability
APQP position reporting is a requirement of all M&M activities and must be applied to the next:
New Product introduction/ relaunch.
Changed/ modified product release.
Launch of a new production site.
Significant process changes (new facilities/ toolings).
High impact suppliers.
Carry over issues.
Part Submission Warrant (PSW) necessity according to the MQS Mahindra Development Part Endorsement Process Manual.
2. 0 APQP Fundamentals
2. 1 Teams
The first rung on the ladder in the Advanced Product Quality Planning Process is to assign lead responsibility for each APQP Factor. This head establishes a cross-functional team to complete the aspect requirements promptly. Effective Product Quality Planning requires a cross-functional team including representatives from Product Development, Developing Engineering, Manufacturing Plants, Purchasing, Quality, Field Service, Sales, Suppliers, and Customers, as appropriate.
2. 2 Elements
This guideline targets 23 Key APQP disciplines, identified as APQP elements. These elements, when summarized and reported, speak the product quality planning status of your programme.
2. 3 Adjustments
If the program is considered to be low risk, the APQP leader may miss certain APQP elements. For example, if the product is carry-over with small changes, existing control strategies can be utilized and/ or product packaging evaluations may well not be needed. The cross-functional team must agree to all deviations from the APQP process. In case the team agrees that an element is not required, the function should write "N/A" for "not appropriate" in the remarks portion of the APQP Position Report (Annexure 1).
The APQP Business lead/Support Tasks are recorded in Section 5. 0 APQP Factor Description, of the guideline.
2. 5 APQP Elements in MPDS
The alignment of APQP elements is done using the timing plan of the Mahindra Product Development System (MPDS).
2. 6 APQP Process Flow
Figure 2 shows the generic APQP Process Flow
Figure 1
APQP TIMING PLAN
MPDS Gateways
SI : Strategic Intent
SC : Strategic Confirmation
PA : Programme Approval
VV: Virtual Validation
PC : Program Confirmation
PR : Product Readiness
PP : Production Prove-out
SO : Signal Off
LR : Release Readiness
J1 : Job 1
FS : Final Status
SI
J 1
FS
PC
PR
PP
SO
LR
SC
PA
VV
Figure 2 : Generic Process Move - APQP
End
GREEN
YELLOW/RED
Risk Evaluation Y/R
APQP
Assessment
APQP Status G/Y/R
Major Review Reaching including APQP Diagnosis Results
Start APQP Reporting
Initiate APQP Process
Management
establishes cross-functional team
Criteria for APQP
Start
3. 0 The APQP Status Report
3. 1 Purpose
The APQP Position Survey summarises the status for the 23 APQP elements. The position report helps communication between Product Development, Manufacturing Engineering, Manufacturing Vegetation etc. It also offers a dated record that future programmes for research.
3. 2 Position Reporting Responsibility
For each one of the 23 elements, there is a lead responsibility defined. This lead function obtains the necessary suggestions/support from other afflicted functions and consolidates it into a G/Y/R (Green/Yellow/Red) status (per element) on the APQP status statement form. (MQS/APQP/F01)
Reporting Requirements
The Job Team consolidates the APQP status article and present summary to senior management by any means major Programme Reviews/ Gateways. Action plan is well prepared for those Yellow & Red status.
Ratings and Assessment
4. 1 G Y R Status
Green-Yellow-Red position communicates the progress toward the successful project conclusion of elements by the program need time frame. Program need time frame is the last possible night out an aspect can be completed rather than adversely impact quality, cost or timing of this program. The "GYR Status" column of the statement shows the examination for each factor. Explanations/Risk factors for Red, Yellow, and Green are detailed in the stand below.
Risk
Colour
Definition
High
Red
Target times and/or elements are at risk. A restoration Action Plan is unavailable and/or executed, or the Action Plan does not achieve program targets. Late on time.
Moderate
Yellow
Target dates and/or elements are in risk, but a restoration Action Plan has been developed to achieve program goals, and has been approved by the appropriate Project Team. Focus on time frame can be found with management support.
Low
Green
Target schedules and elements are on track and meeting aims.
Each element will be recognized by relevant documented evidence like accounts, circular, filled format, quality documents, scanned signoff duplicate etc. For this function MQS & PQO suggests the utilization of appropriate softwares like Excel, Term, Electric power point, MS Task, etc with hyperlinks to the doc.
Any item once become red will remain red & Yellow/Green will be superimposed properly to show latest status.
4. 2 The 8 Emphasis Elements :
For all 23 elements, quality anticipations are described in this Guide. From the 23 elements, the next 8 elements are believed as Concentrate Elements :
Design FMEA
Design Verification Plan
Prototype Build Control Plan
Manufacturing Process Move Chart
Process FMEA
Pre-Launch Control Plan
Operator Process Instructions
Production Control Plan
These elements when finished with Quality and On Time lay the building blocks for Program success.
The 8 Concentration Elements are evaluated for Quality of Event using Concentration Element Score Checklist.
4. 3 Status Report Information :
Build Level : Indicates the level of Build such as Executive Prototype, Confirmation Prototype, Production Trial Run, Job # 1# 1, etc.
PIST : Ratio of Inspection factors that satisfy Given Tolerance (all details).
PIPC : Ratio of Indices which are Process Capable (Percentage of Critical & Significant Characteristics with Pp & Ppk higher than or add up to 1. 67 for the pre-production period and Cp and Cpk greater than or equal to 1. 33 for production phase).
SC & CC (Special Characteristics) : All products and functions have features identified by characteristics which are essential and have to be managed. However, some characteristics called special characteristics require extra initiatives to minimise the risk of potential adverse consequences.
Special Characteristics contain -
1. Critical Characteristics are those product or process requirements that affect compliance with government rules or safe vehicle/ product function AND which require special actions/ settings.
Product or process requirements range from dimension, specification, tests, processes, assemblage sequences, tooling, joints, torques, welds, attatchments, component use etc.
Symbol :
Severity Score : 9 or 10 for just about any occurrence ranking.
2. Significant Characteristics are those product, process, and/ or test requirements which are essential for customer satisfaction AND for which Quality Planning activities must be summarised on a Control Plan.
Symbol :
Severity Ranking : 5 to 8 Occurrence Ranking : 5 and above
For further details please send Charachteristics Classification Guide,
MQS/CC&SC/GL01
The 23 APQP Elements
5. 0 APQP Component Description Description DescriptionThe following internet pages include an in-depth view of the 23 APQP elements. Each factor is put into six independent areas. These areas are :
Definition - recognizes the drive behind the factor.
Expectations - identifies the requirements for the component.
Lead Responsibility - recognizes the function accountable for lead reporting. Identifies function that all others will support in conclusion of the component.
Support function - recognizes the support functions that will provide input to the Lead Responsibility.
Timing - Recognizes the initial and final Gateway timing for the factor with respect to Total Job Work Plan (TPWP).
Deliverables - reveals the items that must be completed during time structures specified for the component.
.
11. Sourcing Decision
Definition
Sourcing Decision is a formal customer dedication to work on a timely basis with internal and exterior suppliers on the programme.
Expectations
The Sourcing Decision is completed and communicated to internal and external suppliers prior to the Programme Need Time frame.
The sourcing need times for many components, systems and vehicles are set up.
Lead Responsibility
Project Team/CFT for in-house sourced components / aggregates.
Material Management. (MM)
Support Functions
Supplier Upgradation
Product Development
Strategic Sourcing
Manufacturing Plant
Manufacturing Engineering
Timing
Initiate Milestone < PA >
Finalise Milestone < VV >
Deliverables
Establish a Timing Arrange for completion of Sourcing Decisions.
Start communication with potential in-house manufacturers for "make parts" and with suppliers for "buy" parts.
Identify long -lead items (i. e. sourcing for new facilities, execution of single sourcing strategies for Assembly Crops, etc. )
Evaluate the percent of conclusion for the Sourcing Decision Component at the beginning of each month between < PA> and .
Sourcing Decision for long-lead items is completed and communicated.
Open issues are recognized and agreed upon by Task Team/CFT.
The Soucing Decision is completed and communicated.
22. Customers Source Requirement
Definition
The Customer Input Requirements Factor can be used to initiate the Quality Planning process through id of design criteria and program requirements.
Quality Function Deployment, (QFD) is one of the mechanisms to generate the Customer Input Requirements.
Expectations
Design goals (specified through customer review) are translated into tentative and measurable design objectives.
The Task Team/CFT must obtain preliminary system and part designs and specifications from R&D Centre including
- Product Assumptions
Functional Performance
Weight
Material
Reliability and Quality goals are proven based on
Prior model product and process concern history
Customer would like and expectations
Programme objectives
Reliability bench-marks
The stability and quality goals must are the following:
Useful life Reliability Targets
Warranty Targets ( R/1000)
Incoming quality focuses on (parts per million, defect levels, scrap rates)
Functional Targets
Note: The aforementioned goals should be supplied as appropriate to the machine, subsystem, or aspect.
The Program Timing Plan is set up to meet the customer needs and goals by identifying the Timing Requirements for the next:
Tasks
Assignments
Events
Programme Timing Date must be communicated for the following:
Programme status reviews
APQP Plans
Design Freeze
2Prototype builds
In Herb Dates
Job #1
Affordable cost targets have been communicated for the vehicle, system, sub-system and components.
Capacity Planning amounts have been provided to the company (external and inside)
A list for Key Contact Employees within M&M - the Project Owner, Project Supervisor, Design Leader, Processing Engineering Leader, Introduction Leader, MM Leader, Supplier Upgradation Leader yet others as appropriate - is set up. The list should include name, location, e-mail address and contact number.
Lead responsibility
Product Development
Support Functions
Manufacturing Engineering
Manufacturing Plants
MM
Marketing
Project Team/CFT
Assembly Herb assigns a Release Manager to aid all necessary activities at the Milestone and beyond. The Set up Place prepares a want set of more suitable product and process advancements. The Desires List is ready based on customer data and making process features of current functioning creation models. When necessary, quality, cost, and timing data shall be presented to lead activities.
Timing
Initiate Milestone
Finalise Milestone
Deliverables
Establish Plans to build up:
Design goals
Reliability and Quality goals
Programme Timing
Cost Targets
Capacity Planning Volume
- Key Contact Personnel
2The Programme Steering Team identifies and supports the criteria discovered in the prospects.
A processing strategy is discovered and available.
The primary Product and Business Targets are identified in sufficient aspect to initiate Executive tasks at the Milestone.
The Programme Center Team is diagnosed.
Resources are determined and devoted by all influenced functions.
The Total Program Work Plan (TPWP) is developed and decided after by the Programme Main Team including APQP deliverables.
The making requirements (must/ wants) can be found, consolidated and published to the Programme Primary Team.
Objectives, Focuses on and Programs for the above desired objectives are completed, established and communicated to all or any resources and planning activities.
The TPWP (including APQP deliverables) is authorized off.
33. Design FMEA
Definition
A Design or Principle FMEA is a organized approach (utilized by the design liable team) which assures that potential design failure modes and associated causes are believed and resolved.
Expectations
DFMEAs are led by Product Engineering, well prepared with a cross-functional team, and follow the rules laid down in the MQS FMEA Manual.
DFMEAs plan new product features, technologies, and product development quality concerns unresolved during the previous model life-time.
DFMEAs are crucial in producing Prototype Build Control Blueprints and the Creation P/ FMEAs.
Unanticipated failure modes came across during design verification trials must be dealt with in the D/ FMEA.
Potential Special Characteristics & are revealed.
Lead Responsibility
Product Development
Support Functions
Manufacturing Engineering
Manufacturing Plants
Customer Care
Timing
Finalize Milestone
Deliverables
Initial
Establish a list of Principles, Systems, Sub-systems etc on which DFMEA needs to be conducted and write out a DFMEA Timing Plan.
Intermediate
Review percentage of DFMEA completion by any means Milestones between and
Final
100% of the DFMEAs are complete and everything necessary activities to minimise quality hazards are carried out.
Potential & are determined.
4 Design Reviews
Definitions
Design Reviews are regularly slated conferences led by the design accountable activity and must include any affected areas, such as, Processing Engineering, Plant staff etc. The review process includes the next:
A group of confirmation activities that tend to be than anatomist inspection.
An effective solution to prevent problems and misunderstandings.
Provide a device to monitor improvement and are accountable to the management (like the review of APQP open issues)
Expectations
The Design Feasibility concerns are settled in time to aid each build In-Plant Date.
Review the progress of the Design Confirmation Plan and Report (DVP&R)). Unanticipated failing modes came across during design confirmation testing must be tackled in the DFMEA.
Review any open APQP issues.
Review the improvement toward achieving consistency, quality, cost and timing focuses on.
Lead Responsibility
Product Development
Manufacturing Engineering
Manufacturing Plants
Customer Care
MM
Deliverables
Develop a Design Review Plan.
Define jobs and responsibilities
Develop a Design Review work plan one month before the first Design Review
4
Evaluate the progress of DVP&Rs
Review the significant and critical characteristics determined in the Anatomist Specifications.
Concerns are determined at each Milestone from to
100% of the wide open design issues are resolved
The Job Team/CFT present the lessons learned from the Program.
For further details please send Design Review Guide,
MQS/DR/GL01
5Design Confirmation Plan &Report
Definition
The Design Verification Plan & Statement (DVP&R) is a report listing the anatomist evaluations, tests, and reports required to establish a design fit for use in the intended environment and meets the customer influenced aims and the intention with which the product / process was designed. The look confirmation plan has a correlation with the client Input Necessity.
Expectations
The DVP&R is a team approach
Identification of specific lab tests, methods, equipment, popularity criteria, sample sizes, design level and timing must be contained in the DVP&R.
Tests must include variant within tolerance on team decided on product characteristics.
The Design Verification must include:
Test requirements for design, materials, or manufacturing process that connect with the creation trial.
Tests, which talk about for the client usage account and duty routine.
Tests which talk about the useful life of the merchandise.
Tests which addresses the consequences of the external environment (climate, highway surface conditions etc)
Tests which treat the effects of physical interfaces between components or systems.
Lead Responsibility
Product & Stability Engineering
Support Functions
Manufacturing Engineering
Manufacturing Plants
Customer Care
Support Functions have skilled workers assigned to examine and verify the DVP&R results and standards options for significant and critical characteristics.
Applicability
Design Verification Programs and Reports are being used for the next schedules,
Development Prototypes.
Product Validation.
Product Life Routine.
5Design Verification Plans and Reports include the following tests
Engineering Development Tests: Performed during product design for functional development, for detecting time centered failures.
Design Verification Checks : Performed to show that the look samples meeting production intent environmental, useful, reliability and strength requirements
Production Validation Testing: Performed to demonstrate that the look samples from the creation environment meet all requirements similar to create Verification testing and assure that no adverse parameters have been introduced.
Continuous Conformance Testing: Performed by using an on going basis to assure contained compliance to all or any Product &Process requirements.
Timings
Initial Gateway
Finalize Gateway
Deliverables
Develop the DVP&R and appropriate review process
The DVP&R is complete and the identified metrics enable comparison with goal metrics at Executive Prototype review.
DVP&R is kept up to date and a draft of the Anatomist specification is offered according to MPDS Guide.
The DVP&R is complete in order to support the Verification Prototype (VP) builds.
All Engineering technical specs, up to and including job #1 design level are affirmed and released.
All verification and validation checks are completed.
6Subcontractor APQP Position (Tier 1 Company)
Definition
The Subcontractor APQP Status identifies and reports on the condition of an external Company or Subcontractor's APQP process. It is required of Supplier to cascade APQP requirements to their suppliers or subcontractors and do APQP reviews as appropriate. The results of the reviews are summarised on the APQP Status Report.
Expectations
All suppliers must determine risk and designate the amount of their suppliers APQP contribution.
Subcontractors that affect significant and critical characteristics must follow all APQP disciplines.
Suppliers will allocate sufficient resources to work with their subcontractors as part of the cross-functional APQP effort.
Suppliers will keep regularly scheduled APQP position reviews with the subcontractors.
Concerns are reported to the customer and action strategies are developed for elements that not meet quality, cost and timing aims.
Lead Responsibility
MM
Support Function
Supplier Upgradation.
Timing
Finalize Gateway
Deliverables
Communicate to all or any relevant suppliers the expected APQP deliverables consistent with Programme Need Times (In Plant Dates).
Provide a Subcontractor APQP position at each Milestone
100% of approved PSW parts supplied before Gateway
100% of the supplier's available issues are fixed to support on-going production
Definition
The Facilities, Tools and Gauges component identifies the new, additional, restored and relocated resources essential to manufacture the client given product at selected variety and quality levels.
Expectations
Facilities, planning approval, drawings and utilities must be included on the Product Timing Plan and financing endorsement must be complete.
Machinery FMEA needs to be completed before releasing the look Approved Print (DAP)
SPC & MSA and acceptance standards must be team approved before sourcing of Facilities, Tools or Gauges can be approved.
Trial goes should occur at the device builder's location to meet the criteria all Facilities, Tools and Gauges.
All corrective activities for Facilities, Tools and Gauges not achieving customer requirements must be completed before the Production Trial Run.
Facilities, Tools and Gauges must be sent, installed and approved prior to the Development Trial Run.
Lead Responsibility
Manufacturing Engineering
Support Functions
Manufacturing Plants
Project Engineering
Asset Management
Timing
Deliverables
Establish a Production Strategy.
New Solutions are revealed.
Hard things for manufacturing process facilities and complexity are set up.
Long lead money is determined for major Facilities, Tools and Gauges at the Milestone.
7
Tooling for the VP0 build is validated and available before Gateway clearance
Readiness for PP(Development Proveout) assembly is affirmed at before Gateway clearance
Facilities, Tools and Gauges are installed &listed in the Process Sheets.
Equipment security is verified.
Concerns are fixed.
8Prototype Build Control Plan
Definition
Prototype Build Control Plan (PBCP) is a description of the control factors which will be used to create and assemble a prototype build. Inside the control plan evaluation process, PBCP is the first synopsis document. This file is essential to align the liable activities process steps to both the significant / critical product characteristics and customer targets.
Expectations
A cross-functional team led by the merchandise Engineering builds up the Prototype Build Control Plan.
The Prototype Build Control Plan is to be assessed at each Design Review and is an essential part of the Team Feasibility Commitment.
All relevant files of Part Quality Inspection before Build are necessary.
Lead Responsibility
Product Development
Support Functions
Manufacturing Engineering
Manufacturing Plants
Timing
Finalize Gateway
Deliverables
Establish a work plan for Prototype Build Control Plan development.
Review the percentage of Prototype Build Control Plan completion at each design review.
The Primary Prototype Build Control Plan is offered by Gateway
A draft of the anatomist specifications necessary for the PBCB is manufactured available at Gateway .
All relevant drawing and engineering standards results, upto and including Job 1, is summarized in the Prototype Build Control Plan.
All significant/critical characteristics are researched through the prototype build stage.
Lessons discovered are revealed.
Feasibility determination of last Prototype Build Control Plan characteristics is available.
9Prototype Builds
Definition
The Prototype Builds Aspect entails the manufacture or assembly of components, systems or sub-systems, and assembled vehicles which will be supplied to the client for builds developing before the Verification Prototype (VP) Build stage.
Expectations
All customer prototype material will meet the subsequent requirements by the
In Plant Time frame.
Correct level parts
Customer specification data.
Customer approval for those non conformances.
The Prototype Build Control Plan was used in the production or set up of the Prototype Builds.
Lead Responsibility
Product Development
Support Functions
Manufacturing Engineering
Manufacturing Plant
MM
Timing
Finalize Gateway
Deliverables
Timing Plan for Prototype Builds is set up.
100% of the parts are available prior to the Milestone.
All designed Prototype Builds are good Timing Plan.
Quality level is confirmed based on the requirements proven in the Prototype Build Control Plan.
Concerns are identified and documented.
9Timing Arrange for VP Prototype Builds is set up.
PSW position is fully determined for everyone parts necessary for every single prototype build.
All planned Prototype Builds are based on the Timing Plan
Quality level is confirmed based on certain requirements established in the Prototype Build Control Plan.
Concerns are identified and noted.
For complete Build classification and its software please refer MQS website under MPDS Section.
Please send Supplier's Master Plan for build details (MQS/APQP/F 021)
1010. Pulling and Specifications
Definition
The Pulling and Specifications Aspect identifies all executive drawings, CAD data, materials specifications and engineering specifications.
Expectations
The Program Need Schedules must be communicated to the customer.
Note: the Drawing and Specifications Programme Need Particular date is the last possible date the provider can agree to a design change and support PSW (Part Distribution Warrant) delivery at the Material Required Day.
PPRF/PR drawings can be applied for protobuilds.
Change cutoff for final pulling release should take place before
Pre-launch build.
Drawings and specs must include
Engineering standards tests
Product Validation Test requirements
The Product Development / Production Engineering personnel who'll be evaluating drawings and specifications to meet Program Affordable Cost and Quality requirements are determined.
The pulling information and anatomist specifications will be utilized as a prerequisite to the Prototype Build Control Plan.
Lead Responsibility
Product Development
Support functions
Manufacturing Engineering
Manufacturing Plants
Timing
Finalize Gateway
Deliverables
Initial
Establish a Timing Plan to support all activities and build phases with Drawings and Features.
Assess the percent of completed drawings and technical specs at each Gateway between to .
The Primary BOM (Costs of Materials) is established at Gateway
CAE research is complete and everything necessary drawings are for sale to the Engineering Prototype Review.
10All necessary drawings are up dated and a draft of the Anatomist Specification is available.
The BOM (Expenses of Materials) reflecting PDB content is packed into Metaphase (Executive Release System) at the Gateway
100% of the drawings and Engineering Specifications are up to date up to and including Job1 design level, are made available at the Gateway
100% of the Drawings and Engineering Specifications are modified.
All service parts are released.
11 Clubs Feasibility Commitment
Definition
The Team Feasibility Factor determines whether the proposed design can be made within the guidelines. A cross-functional design review team is charged with examining design feasibility. Once workability is established, the Program Management Team undertakes the duty of following the design review process and reassessing feasibility for just about any design or part change that might occur during part development.
Expectations
The design review team must be satisfied with the following conditions:
The design is fit for intended use
The design can be made, assembled, tested, packed and shipped in sufficient quality to the customer on program.
Major feasibility concerns must be solved before the Development Trial Run.
The production or assembly herb must determine risk and determine which with their suppliers must complete a feasibility analysis. Subcontractors who have an effect on significant/ critical characteristics must complete a feasibility assessment.
A Team Feasibility Dedication is given if all activities agree to be able to create a product within specification of significant / critical characteristics layed out in the relevant control plan.
The team must establish a formal feasibility document
Lead responsibility
Product Development
Manufacturing Engineering
Support Functions
Manufacturing Plants
Project Engineering
MM
Timing
Finalize Gateway
11Deliverables
The Team feasibility determination is scheduled relative to the Design Review Timing Plan.
The team feasibility commitment is usually to be assessed at each Design Review.
Review the Prototype Build Control Plan Characteristics.
All activities consent to have the ability to produce the product in line within the specs of significant / critical characteristics outlined in the relevant control plan.
All feasibility concerns are fixed and necessary product and process changes are slated to be completed prior to the 1 PP (First Production Proveout) build phase.
12Manufacturing Process Move Charts
Definition
The Making Process Flow Graph is a visual representation of the current or proposed sequence of manufacturing process movement.
Expectations
A Manufacturing Process Flow Chart is developed as input to PFMEAs with a cross-functional team led by Creation Engineering.
Lead Responsibility
Manufacturing Anatomist.
Support Functions
Manufacturing Crops.
Product Engineering
Timing
Finalize Gateway
Deliverables
Develop an idea to determine process flow charts for new techniques / technologies, based on the PFMEA routine.
Process bed sheets initiated at.
Manufacturing Process Circulation Charts can be found to start PFMEAs
100% of Developing Process Flow Charts can be found.
Final Process Sheet available before .
For further details, please refer Guideline on Dynamic Control Planning,
MQS/DCP/GL01.
1313. Process FMEA
Definition
A Process FMEA is a organized approach employed by a manufacturing dependable team to make sure that potential process related failure methods and their associated causes have been considered and dealt with.
Expectations
All PFMEAs are ready by the cross-functional team led by Production Engineering following MQS FMEA manual.
Quality risks determined from DFMEAs, which can't be fixed through Product design changes, require the initiation of the PFMEA.
PFMEAs must be set up for everyone major quality concerns not fixed during the current production model year, all new processes/ systems, and new product features.
A finalised DFMEA is not really a mandatory prerequisite to perform a PFMEA.
Lead Responsibility
Manufacturing Engineering
Support Functions
Product Development
Manufacturing Plants
Customer Care
Timing
Finalize Gateway
Deliverables
Establish a PFMEA plan in line with the above described prospects.
Initial PFMEAs are established for new or critical systems.
100% PFMEAs are performed in line with the development plan and necessary activities are identified and organized before gateway clearance.
100% PFMEAs are performed and everything identified actions are executed before .
A list of established & is offered.
For further details, please refer MQS Guide on Potential Failure Mode & Effects Evaluation, MQS/FMEA.
14Measurement System Evaluation
Definition
Measurement Systems Evaluation assesses the variation of the measurement system and can determine whether the dimension system is satisfactory for monitoring the procedure.
Expectations
The appropriate Way of measuring Systems Evaluation methods, standard acceptance levels, and statistical and analytical requirements will be performed following MQS/MSA/GL01Guideline.
All way of measuring systems (gauges and test equipment) must be changed to represent the latest anatomist part level prior to the Production Trial Run.
The Dimension systems development plan must follow the advancement of the Control Plans (Prototype, Pre-launch and Creation)
The customer must be given the opportunity to review and concur with the gauges and test equipment research results before the Creation Trial Run.
The Way of measuring System Analysis for is essential and must be repeated and approved pursuing all measure and test equipment alterations.
Lead Responsibility
Manufacturing Engineering
Support Function
Manufacturing Plant
Product Development
Timing
Deliverables
Establish measurement systems development plan consistent with Prototype Build Control Plan characteristics.
Develop a Timing Plan for measurement equipment adjustments and execution of new systems.
The Dimension Systems Analysis is in line with the programme build schedule
100% Dimension Systems are assessed for hold over parts and necessary improvements are identified 100% Way of measuring Systems are diagnosed.
14100% Measurement Systems Evaluation is performed and necessary modifications are revealed.
100% measurement potential approval of all measurement system covering all significant / critical characteristics as outlined in the Development Control Plan.
For further details, please refer Guideline on Way of measuring System and Equipment Ability, MQS/MSA/GL01.
1515. Pre-Launch Control Plan
Definition
The Pre-Launch Control Plan is a written information of the dimensional measurements and material and functional exams that will happen after prototype build and before full creation.
Expectations
Development of the Pre-Launch Control Plan is led by Processing Engineering, prepared with a cross-functional team and can follow the outline provided in the MQS APQP and Control Plan Manual.
The Pre-Launch Control Plan is set up through the prototype build phase.
Results from the Prototype Build Control Plan and DFMEA offer an outline for the Pre-Launch Control Plan.
Lead responsibility
Manufacturing Engineering
Support Functions
Manufacturing Plants
Product Development
Timing
Finalise Gateway
Deliverables
Develop a Timing Intend to establish Pre-Launch Control Programs.
Assess the conclusion position of the Pre-Launch Control Plan contrary to the Programme Need Time.
The Pre-Launch Control Plan is 100% complete to aid the 1PP build stage.
For further details, please refer Guideline on Active Control Planning,
MQS/DCP/GL01.
1616 Operator Process Instructions (SOP or SOS)
Definition
Operator Process Instructions express the facts of control buttons and activities that operating workers must perform to produce quality products.
Expectations
Operator Process Instructions are developed by a cross-functional team led by Processing Plant
Operator Process Instructions identify all process steps essential to create a quality product, you need to include all essential visual helps and/ or comprehensive instructions to aid the production providers.
Lead Responsibility
Manufacturing Plants
Support Functions
Manufacturing Engineering
Timing
Finalise Milestone
Deliverables
Develop a Timing Plan for release of Process Instructions.
Plants begin researching Manufacturing Engineering steps to recognize necessary visual aids for creation.
The Assemblage Process is available for specific, critical or new systems
Assess the improvement of Operator Process Instructions based on the Timing Plan to ensure availability of an initial Process at the PP build phase.
The period between and will be used to verify and finalise the Operator Process Instructions
Plants have all visible aids identified.
Operator Process Instructions are 100% in place before
For further details, please send Operator Process Instructions/SOP Guideline,
MQS/Operator Process Teaching/GL01.
1717. Packaging Specifications
Definition
The supplier of a product must ensure that individual packaging for delivery (including interior partitions) was created and developed. Customer presentation standards should be utilized wherever available.
Expectations
Packaging requirements are decided after by the provider and the acquiring plant.
Packaging evaluation must test the product packaging under the expected conditions of travel and materials handling.
The packaging design must ensure that the merchandise performance and characteristics will stay unchanged during packaging, shipment and unpacking.
Feasibility of presentation is assured during Design Reviews.
Lead Responsibility
Manufacturing Anatomist.
Support Functions
Product Anatomist.
Manufacturing Crops.
Timing
Initiate Gateway
Deliverables
Develop a Timing Arrange for presentation development.
At each Milestone, product packaging design is evaluated for appropriateness to the expected part quality level.
All necessary product packaging trials are conducted during the PP Production Trial Run
All packaging features can be found. All presentation facilities are in place at the suppliers and/or individual plants.
For further details, please refer Packaging guideline for way to obtain creation parts,
MQS/PKG/GL01.
1818. Development Trial Run
Definition
The creation trial run is a validation of the effectiveness of the creation and assembly techniques using development tooling, equipment, environment (including development providers), facilities and routine times. Output of the Development Trial Run is used for Production Part Agreement and Production/Quality Planning Sign-Off.
Expectations
The Pre-launch Control Plan is used during the Development Trial Run.
The Development Trial Run must be used to verify or add linkages between product and process characteristics.
Preliminary Operator Process Instructions are implemented during the Creation Trial Run.
Corrective design and process actions must be established for concerns discovered during the Production Trial Run.
Lead Responsibility
Manufacturing Vegetable (Launch Supervisor).
Support Functions
Manufacturing Engineering
Product Development
Timing
Initiate Gateway .
Finalize Gateway .
Deliverables
A Timing Arrange for the Production Trial Run is made.
A Timing Plan for operator training is established.
100% PSW Status is identified for every single build trial.
All product and process concerns are fixed before the start of FEU(Field Evaluation Unit) build.
Completion of operator training is evaluated frequently between Milestones and .
Facilities, tools and gauges are integrated.
All product and process concerns are resolved.
Operator Process Instructions are finalised and set up.
The Development Control Plan is finalised and set up.
Production validation evaluation is completed.
Approved PSW parts are provided. and Operator training is completed.
1919. Creation Control Plan
Definition
The Development Control Plan is a written description of the systems for controlling parts and processes during full production.
Expectations
The Development Control Plan is developed by a cross-functional team led by Production Engineering, and is to follow the outline provided in the MQS APQP and Control Plan Manual.
The results of the prototype builds and the pre-launch control plan provides a basis for the Development Control Plan.
Lead Responsibility
Manufacturing Place (Launch Manager).
Support Function
Manufacturing Anatomist.
Timing
Finalize Milestone
Deliverables
Develop a Timing Plan for the development of the Production Control Plan.
Preliminary Production Control Plan is 100% available before the FEU (Field Analysis Device) build period.
Post - FEU, the Production Control Plan is ready and properly modified and in place.
The Production Control Plan is ready for on-going production.
All engineering specs are analyzed.
All significant/critical product and process characteristics managing the make of parts and vehicle assembly (including car paint) are included in the Production Control Plan.
For further details, please refer Guideline on Dynamic Control Planning,
MQS/DCP/GL01
2020. Initial Process Capability Study
Definition
The Primary Process Capability Analysis is a statistical assessment of the ability to produce product within specs.
Expectations
Preliminary Process Capability studies should be performed following MQS Guide.
The statistical and analytical techniques used to ascertain ability must be satisfactory to the client.
Preliminary Process Capacity studies must be performed as documented in the Pre-Launch Control Plan.
Preliminary Process Ability studies must be completed and the customer given the chance to review, before Creation Part Endorsement.
Lead Responsibility
Manufacturing Engineering
Support Functions
Manufacturing Plants
Timing
Deliverables
Begin the process capability evaluation for similar techniques.
Develop a Timing Intend to perform statistical studies
100% necessary statistical studies are recognized and the Timing Plan is confirmed
80% capability examination is performed
100% capability evaluation is performed
Concerns are identified and necessary changes for the merchandise and processes are concerned.
The Timing Plan for verification at the PP build phase is made.
For further details, please refer
Guideline on Carrying on Process Control & Process Capability Improvement, MQS/SPC/GL01.
Guideline for Process Probable Studies (Ppk) for Machine & Process Analysis, MQS/Ppk/GL01.
2121. Production Validation Testing
Definition
Production Validation Tests refers to engineering assessments that validate that products made from production tools and functions meet engineering criteria.
Expectations
Parts for Development Validation Examining must be decided on from the Development Trial Run, as per the test sizes and frequencies defined in the Pre-Launch Control Plan.
All customer - specified dimensional, material, useful and reliability exams must be completed preceding to Development Part Approval. If not, appropriate action blueprints and customer approvals are needed.
Lead Responsibility
Product Development / CQA
Support Function
Manufacturing Plant.
Manufacturing Executive.
Timing
Deliverables
Develop a Timing Plan to produce parts, components, systems, sub-systems and vehicles for validation evaluation in line with Engineering Specifications specified in the Pre-Launch Control Plan.
All produced parts, components, systems, and sub-systems are examined before the FEU(Field Evaluation Unit) build phase
All required Executive Specifications are tested and agreement for acceptance can be found.
For further details, please refer Production Validation evaluation (Engine unit) Guideline,
MQS/PV/GL01
2222. Production Part Approval
Definition
Production Part Acceptance is the noted verification that customer executive design requirements are found by the inner or external provider, and the procedure gets the potential to produce to these requirements, where relevant during an actual development run.
Expectations
All items of the MQS "Mahindra Development Part Agreement Process" Manual must be completed and the mandatory documents provided to the customer with the Part Submission Warrant.
Production Part Endorsement is complete before the Material Required Date (MRD) for an individual Plant's Production Trial Run
Lead Responsibility
Manufacturing Flower / CQA
Support Functions
Manufacturing Engineering
Timing
Deliverables
A Timing Plan for the Development Part Approval Process is made.
100% PSW endorsement process is initiated and the total Programme PSW(Part Distribution Warrant) position is evaluated.
100% PSW is approved.
2323. PSW Part Delivery at Materials Required Particular date (MRD)
Definition
PSW part delivery at the Material Required Particular date (MRD) is the ultimate date that totally approved (PSW) materials must be received at the customer's vegetable to support their Development Trial Runs.
Expectations
The customer's Materials Required Night out must be contained in the supplier's Timing Plan.
Production Part Approval requirements must be completed prior to the MRD of the user plant.
Lead Responsibility
Product Development
Manufacturing Engineering
MM
Manufacturing Plant
Timing
Deliverables
Develop the materials In Seed timing for builds between mile stones to
Establish a MRD review process
Assess PSW part delivery rate at each build.
100% approved PSW parts can be found.
Abbreviations
Ad. NOVA - C
Advanced New Overall Vehicle Audit - Customer
CAE
Computer Aided Engineering
CED
Cause & Result Diagram
DCP
Dynamic Control Planning
DFMEA
Design Failure Mode & Analysis
DOE
Design of Experiments
DAP
Design Approved Print
NOVA - B
New Overall Vehicle Audit - Body
NOVA - P
New Overall Vehicle Audit - Paint
PDI
Pre Delivery Inspection
PDT
Plant Driveline Team
PET
Plant Engine Team
PFC
Process Stream Chart
POS
Process procedure sheet
PVT
Plant Vehicle Teams
QCRT
Quick response Concern Resolution Team
SOS
Standard Operating Sheet
SOP
Standard Operating Procedure
SQA
Supplier Quality Assurance
WSS
Work stop standardization
BWT
Basic Working Team
