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ASIAN AUTOMOTIVE STEELS

12.08.10

Customer request CONTRACT Development Marketing Development REVIEW Customer RFQ product documents delivery
Customer request
CONTRACT
Development
Marketing
Development
REVIEW
Customer RFQ
product documents
delivery requirements
(customer statement)
Customer
Credit Critera failed
Credit Check
Marketing
Credit / Audit Report
Project risk assessment
Quotation
reject,
Counter
Request Customer
Vendor information
proposal
Specific Requiremen
SGM / GM authorization
Development
Preliminary RFQ
Manufacturing
RFQ vendor
outsource
CSR
analysis
Purchasing
Engineering
Vendor RFQ
Statement of Deliverables (internal RFQ form)
Vendor feedback
Preliminary process flow
APQP checklist
Draft APQP organization chart
No
go
Vendor
Technical
preliminary
Reject
feasibility
APQP team counter
proposal
proposals
Accept:
Team Feasibility Commitment
m/c cycle time
Costing assumption
Preliminary planning
Development
Project Development Costing
Manufacturing costing
Preliminary project schedule
Project FS
Accounts
FS documents
Document compilation
Marketing
Quotation analysis, Proposal
Quotation letter
Change
request
Management
Marketing
support
GM, SGM Endorsement
Change
request
MD/COO
Inform customer
Close project order
Marketing
approval
Signed quotation
Project Authorization
RFQ rejection
Document submission
Marketing
memo
Customer quotation forms, packaging
Delivery/Acceptance document
No
Customer
Project close
reject letter
Marketing
accept?
from customer
Record in quotation file
LOI /
LOA
Quotation file
Product Design &
Development

ASIAN AUTOMOTIVE STEELS

12.08.10

CONTRACT AMMENDMENT Engineering change proposal & VA/VE Customer ECN/ change product documents delivery
CONTRACT AMMENDMENT
Engineering change
proposal
& VA/VE
Customer ECN/ change
product documents
delivery requirements
Technical concept
study
Technical feasibility evidence
Preliminary
Go/No Go
Counter
GM endorsement, customer endorsement
Proposal
Commercial Feasibility not OK
Commercial feasibility
Team feasibility commitment not OK
study
Commercial Feasibility study OK
Team Feasibility
commitment OK
Start decision
proceed
outsource
Preliminary planning
Not feasible
RFQ approved vendor
Preliminary process analysis
Project Development Costing
Manufacturing costing
Change
request
Vendor RFQ
Preliminary project schedule
Project feasibility study
Vendor feedback
Vendor proposals
Document compilation
Analysis documents
Preliminary quotation
Change
request
Quotation Letter
GM
Counter proposal
Counter propose
endorsement
Forward to MD
MD/SGM
Counter proposal
endorsement
Signed quotation
Project Authorization
Trasmit to customer
Confirmation of receipt
Customer
accept?
LOI / LOA/ PPA ammendment
product
development

ASIAN AUTOMOTIVE STEELS

12.08.10

PRODUCT DESIGN & VALIDATION

LOI / Customer authorization Design Yes, resourcing / No, new design document localization product validation
LOI /
Customer authorization
Design
Yes, resourcing /
No, new design
document
localization
product validation req
avail?
Sample
no
Customer liaison
available?
Correspondents, minutes
Customer product
specs, stds avail?
yes
Customer needs
No / incomplete
analysis
Customer
requirements
Reverse engineering
product
std
Yes; drawing, spec, testing std
Product analysis
QFD / DFMEA
Quality Requirement
Product specification
QFD, DFMEA
analysis
proposal
form
revise
Bill of materials
incoming material requrement
process requirements
Specification list
Product design /
verification
manual calculations
testing list
FEA output
approval
product design drawing
proto pfmea,
control plan
Customer-approved
PIS, testing list
Product validation
Prototype part,
interfaces
purchase / mfg
Test planning/design
Testing
sample parts
documentation
Test eqpt, method
requirement
Sample
purchase
requirement
documents
Fitting, performance
analysis
Test document
Testing arrangement
preparation
equipment prep
Fitting trial checksheet
Testing checksheets
Status
reports
inspection
Sample
Spec
Prototype testing,
checksheet
testing
review /
analysis
template
results
DQCM
testing review / analysis template results DQCM Product document release PRODUCT SPECIFICATIONS Product

Product

document

release

PRODUCT SPECIFICATIONS Product drawing (comp & assy) Testing specification, Part Inspection Standard Packaging specification

(Specifications

not compatible,

emerging

Requirements)

Product

Change

Request

ASIAN AUTOMOTIVE STEELS

12.08.10

PRODUCT DOCUMENT RELEASE

change

Product specification product document draft / update/ correction draft drawing document log update update drawing
Product specification
product document
draft / update/ correction
draft drawing
document log update
update drawing log
request
customer
EC approval
yes
req?
EC Request
no
(customer
preliminary document
review)
approve for final submission
final document preparation
final document
document
check - approve
signed document
document submission
proof of
delivery
contract
customer
ammendment
yes
endorsement
req?
customer-approved document
Document Control
Contract Ammendment
no
Process development
planning

ASIAN AUTOMOTIVE STEELS

12.08.10

PROCESS DEVELOPMENT PLANNING

LOI / LOA + Product Specifications Process requirement analysis Sourcing plan Process flow diagram PFMEA
LOI / LOA +
Product Specifications
Process requirement
analysis
Sourcing plan
Process flow diagram
PFMEA
Special Process characteristics
Production
Process, inspection
planning
Production Control Plan
Pre-launch Control Plan
Factory layout,
manpower plan
Material, component
Engineering
DevelopmentInspection
sourcing
Development Analysis
/ test eqpt spec MSA plan
Development process flow
Process validation plan
Testing inst
development/acq
Prelaunch control plan
Equipment Specifications
analysis
Development project
Test eqpt requirement /
planning
devp plan
Production m/c requistion /eng development plan
Development Project schedule,
resource requirement, cost estimate
Final proposal
preparation / revision
Change
Project Proposal
request
Management
review
change
Authorization to proceed
Confirmed project plan
request
Transmit final proposal
to customer
management approved proposal
Customer
review
Process
Development &
Validation

ASIAN AUTOMOTIVE STEELS

12.08.10

PROCESS DEVELOPMENT & VALIDATION

PROCESS VALIDATION

Authorization to proceed

ENGINEERING DEVELOPMENT

VENDOR DEVELOPMENT

Inst purchase/ devp / mod / training Eqpt purchase/devp/ Vendor selection mod A9 checking aids
Inst purchase/ devp /
mod / training
Eqpt purchase/devp/
Vendor selection
mod
A9 checking aids
inspection jig
Purchasing records
Vendor LOI
checksheet
Part inspection
Agreement
confirmation
Equipment testing /
checksheets
mc
ng
standard devp
not possible
Equip testing checksheet
Vendor
drawing
Change
product
test
Draft PIS
terms
characteristic
equipment
ng
Eqpt
fail
testing
Vendor
arbitration
Devp
Approved checksheets
Hard tooling
Product
samples
Equip / test reports
failed
Line trials
Vendor inspection agreement
development contract / LOA
approved quality checksheets
line operation status OK
improvement areas
Vendor development
Product testing
line improvement
Vendor progress reports
Dimensional inspection
improvement
report, AAR,
testing report
Vendor monitoring
needed
Child
Product evaluation
Line trials
part
Vendor evaluation sample
ng
sample submission
Child part testing
preliminary
Sample approval
Module testing results
PFMEA update
Child part
evaluation
Child part approval
pp appointment
satisfactory
RPN
Vendor PP
Vendor pp summary
Approval Record
MASS
Subsupplier
Vendor PQCM
master parts
PRODUCTION
PQCM
PREPARATION
sign-off
signed vendor PSW
minutes PQCM
Vendor LOA,
draft PPA
draft LOA, PPA
contract nego
term agreement
Vendor PPA

ASIAN AUTOMOTIVE STEELS

MASS PRODUCTION PREPARATION

12.08.10

process development review prelaunch control plan updated prelaunch, production control plan list equipment,
process development
review prelaunch
control plan
updated prelaunch, production control plan
list equipment, instrument, work instruction, QC checksheets, manpower
list material & child part ordering
prelaunch preparation
meeting
prelaunch checksheet updata
prelaunch, production
QC checksheet
equipment servicing,
prelaunch production
prelaunch material
work instruction
preparation
instrument MSA
planning
order
preparation
preparation
not ready
monitoring
prelaunch checksheet complete
prelaunch briefing
small batch
trial production
product, process data
minor
product
issues
audit
process ok
line production
confirmation trial
product, process data
product
major issues
audit
process ok
Process
Quality Council
line run at rate
Development
Enquiry
Customer PQCM/PCPN Sign-off
PQP Summary & Sign-off
Production part
documentation
APQP records
Project Exit Review
compilation
correction
PPAP, Pqcm report
minutes
request
Quality document
PQCM
update
PSW Sign off
project file document update
product quality standard update
Early production
containment
Project APQP doc
QMS update

ASIAN AUTOMOTIVE STEELS

12.08.10

KAIZEN / PROCESS IMPROVEMENT

SCHEDULED PRODUCTION Improvement Operational problem needed? Production no QC report Quality Quality problem
SCHEDULED
PRODUCTION
Improvement
Operational problem
needed?
Production
no
QC report
Quality
Quality problem
problems?
Improvement possible
Problem analysis
Kaizen request for
proposals
Improvement
ideas
Kaizen submission
Additional Testing /
data gathering
Kaizen
Evaluation
Proposal
accepted
Test reports,
data analysis
Project planning
Kaizen proposal
Minutes
project schedule
Temp rigging,
Modification
work inst
Tooling / mc redesign,
fabrication
Temporary production
rigging, work inst
Off-line testing
Problem
resolved?
Target achieved
Supervised
production
Statistical data
Acceptable?

Process ref update m/c maintenance log update

Kaizen award

presentation

m/c maintenance log update Kaizen award presentation Problem description m/c maintenance log update PFMEA updates
m/c maintenance log update Kaizen award presentation Problem description m/c maintenance log update PFMEA updates
m/c maintenance log update Kaizen award presentation Problem description m/c maintenance log update PFMEA updates

Problem

description

m/c maintenance log update

presentation Problem description m/c maintenance log update PFMEA updates process improvement activities update SPC data

PFMEA updates process improvement activities update SPC data update

improvement

project close

improvement project close
improvement project close
activities update SPC data update improvement project close File: Procedure APQP.vsd Page 8 Prepared: AG

ASIAN AUTOMOTIVE STEELS

12.08.10

PROJECT GO/NO-GO DECISION

Volume commitment Material cost quotation Dev cost Process cost estimate Compute costs / pc, capital
Volume commitment
Material
cost quotation
Dev cost
Process cost
estimate
Compute costs / pc,
capital investment
estimate
Standard costing sheets
Marginal cost meet
customer price?
No
Yes
Management
No
prerogative
Full costing meet
customer price?
Yes
Project Authorization Memo
4 TH down & 20
Quotation issue
GO FOR IT!
Inform customer NG