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Appendix Reference Revision
HOGW_4-2_SC-
1 Team Feasibility Commitment Letter(This is a link to the electronic
DIR_23-F01_EN
RFQ)
(Need Sharepoint
7-Feb-17
access to view)
Assigned
Issue Issue Issues Date/Status
No. Origin/Date Description and/or Sketch Responsibility Date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Progress Key:
Issue Identified Action Plan Proposed Action Plan Implemented Issue Resolved
sues
Forecast
Completion
Action Plan Date Progress
Issue Resolved
APQP Tim
Supplier Duns: Part Number(s):
Supplier/Mfg Location:
PPAP Date:
SOP Date:
Actual
Potential Issues exists (comments must be noted)
Supplier Name
NOTE: Supplier Profile Contact information should be reviewed and updated as changes occur.
Contacts Name and Title Mailing Address and E-Mail Address Contact Numbers
Sales Contact
Product Engineer
Quality Resident
Program Manager
in Sales Office
Program Manager
in Manufacturing Facility
APQP Contact
Quality Manager
Quality Engineer
PRR Response
Responsibility
Aptiv Engineering
Aptiv Buyer
Aptiv SQE
A-1 DESIGN FMEA CHECKLIST
Prepared By:
A-2 DESIGN INFORMATION CHECKLIST
A. General
1 Does the design require:
a - New materials?
b - Special tooling?
c - New technology or process?
2 Has assembly build variation analysis been
considered?
3 Has Design of Experiments been considered?
B. Engineering Drawings
14 Are reference dimensions identified to minimize
inspection layout time?
15 Are sufficient control points and datum surfaces
identified to design functional gages?
16 Are tolerances compatible with accepted
manufacturing standards?
17 Can existing and available inspection technology
measure all design requirements?
18 Is the customer designated engineering change
management process used to manage engineering
changes?
D. Material Specification
26 Are special material characteristics identified?
Prepared By:
A-3 NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLIST
a - New equipment?
b - New tooling?
c - New test equipment (including checking aids)?
a - New equipment?
b - New tooling?
c - New test equipment (including checking aids)?
4 Will a preliminary capability study be conducted
at the tooling and/or equipment manufacturer?
5 Has test equipment feasibility and accuracy been
established?
6 Is a preventative maintenance plan complete for
equipment and tooling?
A-3 NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLIST - CONTINUED
Prepared By:
A-4 PRODUCT/PROCESS QUALITY CHECKLIST
b - Available?
c - Accessible?
d - Approved?
c - Reference samples?
d - Inspection logs?
19 Have provisions been made to certify and calibrate
gages and test equipment at a defined frequency
that is appropriate?
20 Have required measurement system capability
studies been:
a - Completed?
b - Accepted?
21 Have initial process capability studies been
conducted per customer requirements?
22 Are layout inspection equipment and facilities
adequate to provide initial and ongoing layout of
all details and components in accordance with
customer requirements?
Prepared By:
A-5 FLOOR PLAN CHECKLIST
b - Properly lighted?
a - Staging areas?
b - Impound areas?
Prepared By:
A-6 PROCESS FLOW CHART CHECKLIST
Prepared By:
A-7 PROCESS FMEA CHECKLIST
Prepared By:
A-8 CONTROL PLAN CHECKLIST
Prepared By:
Person Due
Responsible Date
Revision Date:
Pg. 1 of 1
Person Due
Responsible Date
Revision Date:
Pg. 1 of 3
D
Person Due
Responsible Date
Revision Date:
Pg. 2 of 3
D
Person Due
Responsible Date
Revision Date:
Pg. 3 of 3
ECKLIST
Person Due
Responsible Date
Revision Date:
Pg. 1 of 2
T - CONTINUED
Person Due
Responsible Date
Revision Date:
Pg. 2 of 2
Person Due
Responsible Date
Revision Date:
Pg. 1 of 4
UED
Person Due
Responsible Date
Revision Date:
Pg. 2 of 4
UED
Person Due
Responsible Date
Revision Date:
Pg. 3 of 4
UED
Person Due
Responsible Date
Revision Date:
Pg. 4 of 4
Person Due
Responsible Date
Revision Date:
Pg. 1 of 1
Person Due
Responsible Date
Revision Date:
Pg. 1 of 1
Person Due
Responsible Date
Revision Date:
Pg. 1 of 1
Person Due
Responsible Date
Revision Date:
Pg. 1 of 1
Meeting Plan Checklist
AQE Input
Utilize Program Review Form -or -
Utlize Express Program Review Form
PPAP Requirements
R@R Timing and Requirements
Aptiv's Customer Specific Requirements
Introduction/Instructions to all Aptiv Supplier Websites.
Engineering Input
Latest part prints and specifications
Program Timing / Critical Characteristics
Technical Documents including sub-component drawings.
Program Information such as estimated annual usage, PPAP dates, SOP dates, etc.
Pilot and Prototype requirements and timing.
Key/Critical characteristics for PPAP
Supplier Input
Supplier Scorecard, be prepared to discuss
Updated supplier information (Supplier Profile)
including contact list.
Program Timing including tooling, PPAP, R@R
Supplier issues/concerns caused by Aptiv Aptiv.
Supplier issues/concerns not associated with Aptiv.
Questions/concerns needing to be addressed by Aptiv
1
2
3
4
5
6
CHECK IF IN ATTENDANCE
Aptiv CONTACTS
TITLE NAME PHONE EMAIL
AQE
SQE
BUYER
PROGRAM MGR
PPAP COORDINATOR
COMPONENT ENGINEER
PRODUCT ENGINEER
RESPONSE TEAM
SUPPLIER CONTACTS
NAME PHONE EMAIL
PRESIDENT
QUALITY MANAGER
KEY CONTACT
PPAP CONTACT
QUALITY CONTACT
RUN@RATE CONTACT
Design Review
Identify characteristics that will require controls. (KPC's, KCC's, Forecast
CQC's, QCI's)
Ideally, a six sigma capability is the goal. Note gaps Issues Completion
B between desired and actual, with action plans to close. Description and/or Sketch Responsibility Date Actio
Critical dimensions and interfaces of product
1 KPC's, KCC's, CQC's, QCI's, Pass-Through Characteristic/Feature
2 Fit & Function, Safety Compliance
3 Part Packaging Specification
4 Part Labeling requirements
Forecast
Program Information Completion
C List information required below Details Responsibility Date Actio
1 Platform
2 Model Year
3 Aptiv Estimated Annual Volume
4 Supplier PPAP Due Date
5 Aptiv SOP
6 Aptiv Manufacturing Site
7 Supplier Quoted Tool Capacity (5 days)
Forecast
Product Requirements & Timing Completion
D Record the following if applicable. Details Responsibility Date Actio
1 Prototype requirements.
2 Pre-Production Requirements
3 Other Product Requirements
Has Aptiv received the supplier’s plan for dimensional layout and
measurement of the component? (Should include the measurement
1.1 methods, layout, datums, tools, equipment and fixtures (if applicable)
)
Has the Aptiv Receiving Facility, reviewed and approved the supplier
plan for dimensional layout and measurement?
1.3 (Applicable for sites with a Receiving Inspection)
Forecast
Capability Assessment Guidelines Completion
H List Characteristic(s)
to be used in capability study. Details Responsibility Date Actio
1.1 KPC / QCI (note details in column)
Measurement Equipment #6
6 & Methodology
Forecast
Design Responsible Suppliers Completion
J List all issues/requirements if the supplier is design responsible. Details Responsibility Date Actio
Was a Design Failure Modes & Effects Analysis (DFMEA)
initiated by
1 the supplier?
2 Has the Aptiv PDT reviewed the DFMEA?
Are DFMEA open items addressed on an action plan and
3 communicated to Aptiv's PDT?
manufacturing, controls a key process or directly affects a key product characteristic. A separate program review
sibility document on RFQ.
plating must comply with the AIAG assessment requirements stated in CQ9, 11 and 12. Including qualified auditors
T MEET PROGRAM TIMING (Ctrl-r)
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
313&name=DLFE-103457.xls
Actual
Completion
Action Plan Date Progress
Actual
Completion
Action Plan Date Progress
ame=DLFE-103455.xls
ame=DLFE-103455.xls
Actual
Completion
Action Plan Date Progress
The following instructions are intended to help the AQE/SQE in performing the Program Review. Take a moment to review the
Instructions. The intent of the program review is to engage the supplier in conversations about various aspects of the current
program/parts and determine areas of concern that will need further action.
The form is protected/locked so that users can tab through fields. To allow attachments (such as program rosters) and/or
and/or additional information into any open field within the form, the form can be unprotected. The password is "unlock".
This will allow each user to customize the program review to fit their needs while continuing to use a common form and process.
Pass-Through Characteristic
Is a characteristic/feature where an anomoly only declares itself under certain conditions such as environmental stimulation and cannot be tested
in Aptiv's operations (i.e. soft tie rods, stepper motor with step loss and steering hose with incorrect rubber component.
The first part of the Program Review is an informational list used by Aptiv and the Supplier for better communication.
Fill in the following information as thoroughly as possible:
Date of Review
Supplier -include both the facility name and parent name where applicable
Supplier Duns Code -this is in reference to the manufacturing site producing the product.
Supplier/Mfg Location
Part Numbers
PPAP Date
Description
Platform
Model Year
SOP Date
Supplier Contacts: -List key supplier contacts
Key Contact
PPAP Contact
Quality Contact
Run@Rate Contact
Aptiv Contacts -List key Aptiv contacts
AQE
SQE
Buyer
Program Manager
PPAP Coordinator
Component Engineer
Product Engineer
Response Team
New Risk Level of Product -Once the review has been completed, evaluate the program risk based on your findings.
Sections A through M are used to track the progress of the supplier through various aspects of building a new product. Each section
focuses on a specific area and is as comprehensive as possible.
The first columns will be used to color code each line item. Green indicates completed, Yellow indicates Open with recovery plan,
Red indicates the suppliers process will not meet Aptiv requirements.
The formatting for these three colors has been automated. Go to the cell you want to change, then hit the following key:
for red use "Ctrl-r" for yellow use "Ctrl-y" for green us "Ctrl-g" this coding will also show up in black/white copies with patterns for each color.
.
The columns represented in each section are used to promote communication between Aptiv and the supplier. It also determines responsibility,
forecasts completion dates, action plans, actual completion dates and progress. Each block is expandable to add information as necessary.
2 Year:
3 Volume Annual Usage:
4 Information Peak Weekly Usage:
5 Type of Build:
6 Parts required Date:
7
Forecasted Quantity:
8
Builds PML
9 Build when PPAP is required:
16 The supplier is responsible to register and use the Aptiv Supplier Websites and must be capable to update and access the following:
Supplier Profiles
Supplier Suggestion Program (SSP / SCR)
Problem Solver
Customer Specific Requirements/ Quality Expectations
IMDS system (reportable Chemicals)
22 Comments:
For Semiconductors Run at Rate is exempt. To ensure commitments are met a CAPACITY STUDY is required.
The tab key can be used to move to the next available field in the form to enter data. Similarly,
l
shift_tab will move to the previous available field.
Section B should be filled in by the Supplier (lines 13 to 18). Enter the Supplier Name in the
l appropriate cell and enter the name and date of the authorized Supplier Representative who is filling in
the form.
Section C should be filled in by the AQE. If the part commodity is exempt (see Express form for
criteria)
, it should be listed in the Commodity Exemption letter signed by the Supplier Quality Manager.
l This is expected to be one letter listing all exempted commodities and stored in one location for
reference by all of Supplier Quality.
APTIV Supplier Quality FMEA SEVERITY RANKINGS
Note #1: Any Failure Mode affecting the Vehicle Assembly Plant MUST be ranked an “8” or higher.
Note #2: Any Failure Mode affecting a Aptiv Plant MUST be ranked “5” or higher.
Select from the categories below, using the highest applicable ranking.
Ranking Effect End Customer Vehicle Assembly Plant Aptiv Plant Supplier Plant
10 Hazardous- Potential failure mode affects Potential failure mode may Potential failure mode may Potential failure mode may
without warning safe vehicle operation and/or cause unsafe condition for cause unsafe condition for cause unsafe condition for
involves noncompliance with plant personnel without plant personnel without plant personnel without
government regulation without warning. warning. warning.
warning.
9 Hazardous-with Potential failure mode affects Potential failure mode may Potential failure mode may Potential failure mode may
warning safe vehicle operation and/or cause unsafe condition for cause unsafe condition for cause unsafe condition for
involves noncompliance with plant personnel with warning. plant personnel with warning. plant personnel with warning.
government regulation with
warning.
8 Very High Vehicle/item inoperable (loss Potential failure mode may Potential failure mode may
of primary function)
; failure cause a spill/major disruption, cause a spill/major disruption
mode may cause customer repair, assembly difficulty, at a Aptiv Plant.
walk home, field return, or rework, or sorting at the
durability issue. Vehicle Assembly Plant
7 High Vehicle/item operable but at a Potential failure mode may
reduced level of performance. cause repair, assembly
Customer very dissatisfied. difficulty, rework, sorting at a
Failure mode may cause See Note #1 Aptiv plant.
vehicle repairs at Dealer.
Includes Noise issues
(squeak/rattle)
.
6 Moderate Vehicle/item operable but Potential failure mode may
comfort/convenience item(s)
)
cause special handling of
inoperable/not performing to See Note #1 components at Aptiv-S.
customer expectation (e.g..
Noise)
> 0.86
10 per thousand pieces 7
2 Very High Error detection in-station (automatic gauging with automatic stop
feature)
. Cannot pass discrepant part.
1 Almost Certain Discrepant parts cannot be made because item has been error-
proofed by process/product design.
* Note: Identical to Manual except for Rankings of 6 and 4. Words “OR gauging performed on setup and first piece check”
moved from a detection of 4 to a detection of 6