Supplier APQP Training Advanced Product Quality Planning

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Supplier APQP TrainingAdvanced Product Quality
Planning
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Supplier APQP Overview

• APQP is
• A structured method for defining executing the
  actions necessary to ensures a product satisfies
  the customer.
• Supplier Led
• Required of all designated component
  manufacturing.
• Maximize the opportunity to achieve a defect free
  product launch and beyond.

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Supplier APQP Overview

• Scope To define the process through the sourcing
  decision of a new or modified product by a
  Supplier to Dana to the approval of the PPAP.
• Reasons for APQP
• Cost Avoidance Scrap, Engineering Changes
• Robust Products Durable / Reliable
• Robust Processes Stable / Capable
• Clearly defined understood launch requirements
• Builds solid Supplier relations
• Synergy

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Dana Supplier Quality Manual

• 5. Supplier Advance Product Quality Planning
  (APQP) 
• Suppliers are required to conform to the latest
  edition of the AIAG Advance Product Quality
  Planning Manual, located at http//www.aiag.org,
  for the introduction of a new or significantly
  modified production product to Dana.

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Supplier APQP

• APQP Required
• Program Launches Select Resourcing Actions
• Supplier Responsible for complete APQP
• Supplier Development Engineer validates all APQP
  Elements through documentation and objective
  evidence submitted in the APQP Workbook.
• Supplier Development on-site review only occurs
  for suppliers who consistently fail to submit
  objective evidence to the APQP timeline and/or at
  risk suppliers as identified by the Program Team

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Supplier APQP Status Report
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• In order to initiate APQP Activity with a
  Supplier the following is required
• Date the Dana LOI or Purchase Order Was issued
• Date The Dana Tooling Order was or will be
  issued.
• Prototype Sample quantities and timing.
• Requested PPAP Date
• WITHOUT THIS INFORMATION SUPPLIER DEVELOPMENT
  CANNOT INITIATE THE APQP ACTIVITY.

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Supplier APQP Elements

• What is the requirement?

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Supplier APQP Status Report Elements
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Supplier APQP Status Report Elements
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Supplier APQP Status Report Elements
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Supplier APQP Status Report Elements
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Supplier APQP Status Report Elements
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Supplier APQP Status Report Elements
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Supplier APQP Status Report Elements
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Supplier APQP Status Report Elements

• What are we looking for as Objective Evidence

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Objective Evidence Required Elements 1 - 3
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Objective Evidence Required Elements 4 - 7
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Objective Evidence Required Elements 8 - 10
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Prototype Sample Inspection Requirements
All prototype samples furnished by suppliers
shall conform to the following requirements for
their applicable Dana Product Group.
Commercial Vehicle Light Vehicle Driveline
Technologies - Each part is to be serialized on a
non critical surface (consult with the applicable
Engineering Group for non critical surface
identification). The preferred identification is
Part Number and Consecutive Dash Number.
(Example Part Number -1, -2, etc....). An
inspection report is to be furnished for each
serialized part for all critical/significant
dimensions as designated on either the Dana
Drawing or Engineering Specification. At
minimum, the inspection report shall include -
date inspected, Inspector's signature, part
serial dash number, revision level, part name,
purchase order number, part dimension/tolerance/ac
tual dimension the Gage RR reports for all
inspection tools utilized( for CMM submit a copy
of the current Calibration Certificate).
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Prototype Sample Inspection Requirements
The inspection report shall be in pdf file format
and named with the Dana Program, Part Number and
Date. (Example Program Name_Part Number_
Month-Day-Year.pdf). The inspection report
shall be shipped with the prototype samples.
Prototype samples received without the
accompanying inspection report will be rejected.
Any Metallurgical/Heat Treat/Physical Test
results available for the prototype parts should
be included with the inspection report
furnished. Any additional inspection
requirements, outside of that listed above, will
be delineated on the prototype quote request and
listed on the prototype purchase order. In all
cases prototype samples that do not conform to
the Dana Drawing and/or Specifications shall not
be shipped prior to receipt of an approved
Engineering Change or Deviation. A copy of the
approval document shall be included with the
prototype part shipment.
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Objective Evidence Required Elements11 - 12
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Objective Evidence Required Elements 13 - 15
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Objective Evidence Required Elements 16 - 19
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Objective Evidence Required Elements 20 - 23
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Additional Dana PPAP Requirements
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Safe Launch
The purpose of the Safe Launch Plan is to protect
Dana Facilities from receiving quality
non-conformances during critical new product
launch periods and validate the supplier's
Production Control Plan during volume production
runs. It is in addition to all normal process
inspections and evaluations outlined in the
Production Control Plan and is a post processing,
off-line, separate and independent from the
normal manufacturing process check. Use of any in
process inspection/containment stations requires
the prior approval of Dana.
The Safe Launch Plan shall be in effect for a
minimum of 90 days or the first 5 supplier
production runs, whichever is longer, from the
start of PPAP Approved part shipments to the
receiving Dana facility. If any discrepant parts
are received by a Dana facility during the Safe
Launch period it shall be extended for a
timeframe to be determined by the receiving Dana
facility.
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Safe Launch
Any non-conformances discovered at a Dana
facility during the Safe Launch period require
immediate and irreversible corrective action
within 72 hours of notification. In addition, any
non-conformances discovered at a Dana facility
requires supplier, or supplier designated,
representation on site at the Dana facility to
initiate sorting and containment actions, back
through their organization, within 24 hours.
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Safe Launch
The Safe Launch Plan shall include 100
evaluation of --
All Dana designated Critical and/or Significant
Characteristics (Variable)
All Customer attachment( pass through)
characteristics identified by Dana Engineering
(Attribute)
All Significant Characteristics to the process
identified by the supplier (Variable)
Verification that the packaging and labeling
conforms to the Supplier Packaging Specification
form approved by the receiving Dana facility.
(Attribute)
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Safe Launch
Data from safe launch inspections shall be
forwarded to both the Dana Receiving Plant
SupplierDevelopment_at_dana.com, for each production
lot shipped, so it is received prior to the
production lot.
Product shipped to Dana that has been evaluated
in the Safe Launch process shall be identified by
means of a Green Sticker, attached to every
individual carton, signed by the person
accountable to perform this function.
Failure to implement a robust Safe Launch
Process, containing these requirements as a
minimum, will result in a Supplier being placed
on Restricted Shipping 2 and other possible
consequences.
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Customer Attachment Points
Customer Attachment Points Customer Attachment
Points will be communicated to suppliers by
designation, ( ltCAPgt ), on Dana Product
Drawings. Customer Attachment Points require
Poke-A-Yoke at the source of manufacture. If
Poke-A-Yoke cannot be achieved an alternative
control plan method must be proposed by the
supplier and be approved by Dana.
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Questions