AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.

: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

NEW PRODUCT DEVELOPMENT Page 1 of 15

ASWINI GROUP

REVISION CONTROL

The Revision Control format given below is used for updating revisions in the Procedures and issued along with the
document.

DETAILS
REV. REV. ISSUE
TOTAL NO. REVIEW DATE
NO. DATE DESCRIPTION OF REVIEW NO.
OF PAGES PAGE NO.

0.0 04.01.17 7 All New release 1.0 04.01.17

New product APQP Review

frequency -2 weeks once on timing
1.0 04.01.17 7 7 1.0 04.01.17
plan and discuss with IRM-3 months
once.
0.0 07.01.19 13 All Input-process-output introduced 2.0 07.01.19

1.0 22.03.19 13 2 Scope updated 2.0 07.01.19

 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

NEW PRODUCT DEVELOPMENT Page 2 of 15

ASWINI GROUP
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

NEW PRODUCT DEVELOPMENT Page 3 of 15

ASWINI GROUP

EFFECTIVE
NAME SIGNATURE DATE
DATE
PREPARD &
RELEASED 22.03.2019
BY
22.03.2019
APPROVED H.GIRI
22.03.2019
BY (CEO)
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

NEW PRODUCT DEVELOPMENT Page 4 of 15

ASWINI GROUP

1.0 Purpose

To establish, implement and manage a process for advanced product quality planning, new product development,
production part approval process, process or engineering change control, special characteristics, identification of statistical
tools and cross functional team.

2.0 Scope

This process is applicable to all products in development, pre-launch, Design change, Material Change, Process parameter
Change, Process sequence / Layout Change, Process equipment Change, Relocation, Supplier Change and production.

3.0 Reference

IATF 16949:2016 Clause 7.5.3.2.2, (8.1.1-8.1.2) 8.2, 8.3.1 (8.3.1.1), 8.3.2 (8.3.2.1 – 8.3.2.2), 8.3.3 (8.3.3.2 – 8.3.3.3), 8.3.4
(8.3.4.1 – 8.3.4.4), 8.3.5 (8.3.5.2), 8.3.6 (8.3.6.1)

4.0 Definition / Abbreviations

NPD – New Product Development, APQP – Advanced Product Quality Planning, PPAP – Production Part Approval
Process, ECN – Engineering Change Note, PFMEA – Process Failure Mode and Effects Analysis, CP – Control Plan, PFD
– Process Flow Diagram, WI – Work Instruction, MSA – Measurement System Analysis, OEM – Original Equipment
Manufacturer, CFT – Cross Functional Team, QA – Quality Assurance, UOM – Unit of Measurement, SC – Significant
Characteristics, CC – Critical Characteristics, SOP – Standard Operating Procedure, RRA- Resource Requirement
Analysis, DFM – Design For Manufacturing, CSR – Customer specific requirement.

5.0 Responsibility

HOD : NPD
Team : CEO & CFT

6.0 Input – Process – Output

Input Process (Activity) Output

Safety related Product & its
Manufacturing Processes, Product and manufacturing
Product-safety management
Statutory & Regulatory process safety
Requirements
NPD order with customer input
(Customer Drawings, New Part Samples & Pilot
Product Development
Specification Standard, Sample Batch and Production Approval
part, Customer P.O)
Sample, Pilot & Production
Part Samples Production Part Approval Process
Approval
Internal Process change / Updated PPAP & Customer
Product / Process Change
Improvements / Customer ECN Approval
Process / Product control
New and Existing Product Control Measures
measures
Customer Drawing / Internal Extra Care & Control of Special
Special Characteristics
process Characteristics
Process / product Identification of statistical Tools Statistical Quality Control

Product Realization Cross Functional Team Multi-disciplinary Approach

 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

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ASWINI GROUP

6.1 Product-Safety Management

Safety-related Product & Identification product /process Identification Statutory &

Manufacturing Process safety requirements in the product Regulatory Requirements
(Safety Aspects) realization including delivery and related to Product &
post-delivery activities Manufacturing Processes

Identification of controls for safety- Lessons learned or team

related product characteristics experience in new product
and/or manufacturing process development
parameters

Planning for safety-related product

and/or manufacturing processes
(E.g. Process Flow, PFMEA,
Control Plan, Tool Drawings, etc.)

Initiate necessary Validate the

corrective actions controls?

Send the relevant documents

(Control Plan, PFMEA, etc.) for
customer’s special approval, if
required.

Initiate necessary Customer

corrective actions Approval?

Any changes or transfer Implement the controls for product Ensure product and
of product and/or and manufacturing safety by manufacturing process
manufacturing processes defined RRA, trainings, and any safety throughout the
including customer- changes or transfer of controls. supply chain with
directed sources traceability
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

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ASWINI GROUP

6.1 Product Development

Input Product Development Program(APQP) - Activity Output

Enquiry (Customer Product Development

Drawings, Specification Identify team members and leader to CFT for Scope & Project
Standard, Sample part) NPD and get approval from CEO Development team
Feasibility study,
CFT
Clarification from
Customer for incomplete
information, Technical
Feasibility, Cost Conduct initial meeting with CFT, and collect CSR
Estimation & PO/ LOI customer input (If necessary include
from MK customer representative) and define the
category in APQP matrix.

Prepare timing plan with responsibilities for Timing Chart

Part Drawing,
each activities and communicate to CFT and
Technical Feasibility,
customer.
APQP Matrix & CSR

Voice of the Customer Do Plan and Define Program (phase 1) Process Flow chart
APQP Manual, activities as appropriate. Bill of materials
Timing Plan, Passed history study
Customer Drawing, Component drawing
In-house rejection
data and Business
plan, team experience
and lessons learned

Prepare summary of Plan and define program

using check list.

Review Plan and Define Program (Phase 1) CFT Sign off

for management support

Is reviewed and No Stop the project,

approved by CEO? record the reasons and
intimate to customer

Yes

Review
PrepareProduct
summaryDesign
of Product
and Development
Design and CFT Sign off
(Phase
Development
2) for management
using checksupport.
list
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

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ASWINI GROUP

APQP Phase-1 Output Do Design and Development (Phase 2) Drawing review

activities as appropriate. Review of process flow
chart
Process Flow chart Special Product/Process
Bill of materials characteristics
Passed history study Evaluation of
Regulatory/Statutory,
Component drawing
Environment Health Safety
PFMEA
Productivity goal
Quality goal
Control plan (Prototype)
Tool design/drawing
Tool manufacturing
Gauge/equipment testing
Sourcing of raw
material/BOP’S

No
Is reviewed and Stop the project,
approved by CEO? record the reasons and
intimate to customer
and sign off
Layout plan
Component 2.13 Follow-up results
procurement Sample trail run with production tooling, during product
Ppk study plan equipment, environment (including operator), development
facilities and cycle time 2.14 Operator process
Operator training instruction
Not ok

Phase-2 Output Is reviewed and 2.15 Layout

Drawing review
approved by Inspection report
Review of process flow 2.16 Ppk study result
chart Customer?
Special Product/Process
characteristics Ok
Evaluation of Yes
Regulatory/Statutory,
Environment Health Safety Start Process Design and Development
PFMEA (Phase 3) activities as per APQP manual
Productivity goal
Quality goal
Control plan (Prototype)
Tool design/drawing
Tool manufacturing
Gauge/equipment testing
Sourcing of raw Yes
material/BOP’S Is packaging Follow customer
Follow-up results during standard given by packaging standard
product development customer?
Operator process instruction
Layout Inspection report
Ppk study result No

Prepare sequence / stages of packaging to Packaging standard

prevent the part from damages and rust

Review QMS Manual / Procedures for changes

to produce the product (Use check list A-4)
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

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ASWINI GROUP

Update QMS
Manual / Procedures
and communicate to
Is any change respective
required? departments through
designated channel
No

Prepare proposed process flow chart for

entire process. (Use check list A-6 given in Process flow chart
the APQP manual).
Yes
No

Process Flow Chart Prepare floor plan layout and identify the Floor Plan Layout
(PFC) production process and inspection locations
(Use check list A-5 given in the APQP
manual)

PFC and Product Prepare characteristic matrix and identify Characteristics matrix
drawing relation between the process parameters and
manufacturing stations (process location)

PFC, Customer Prepare process FMEA and identify potential Process FMEA
drawing and customer failure modes and its effects (Use check list
voice A-7 given in the APQP manual)

PFC, Process FMEA Prepare pre-launch control plan and identify Pre – launch control
and special P/P additional Product/Process control to be plan
characteristics implemented until production process
validated.
PFC, Process FMEA,
CP, Floor plan layout, Prepare drawings, WI and SOP for each Stage drawing, SOP
characteristics matrix, manufacturing process. and WI
packaging standard,
handling requirements
and customer
drawings
Special Prepare MSA study plan for gauges / MSA study plan
Product/Process instruments.
characteristics

Special Prepare preliminary process capability study Preliminary process

Product/Process plan for safety and significant characteristics. capability study plan
characteristics and CP

Yes
Is packaging Follow customer
specification packaging
No specification
given by
customer?
Review Process Design and Development
(Phase 3) for management support CFT Sign off
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
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Date: 22.03.2019

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ASWINI GROUP

No
Stop the project,
Is reviewed and record the reasons and
approved by CEO? intimate to customer

Yes

Start Product and Process validation (Phase A

4) activities as per APQP manual

No
Is customer Decide pilot
specified pilot production quantity
production
quantity?
Yes

Pre –launch CP, Run pilot production with production tooling, Pilot production Qty. as
process FMEA, SOP, equipment, environment (including operator), requested by customer Nos.
WI facilities and cycle time or 12 Hours Shift Output

MSA study plan Conduct MSA study MSA study report.

No

Are the results of Find root cause and

MSA study take action as per
acceptable? CAPA procedure

Yes Re plan the study the

measurement system

Preliminary process Conduct preliminary process capability study Preliminary process

capability study plan capability study report
(Pp & Ppk report).

No
Find root cause and Are the results of
take action as per Pp & Ppk >1.67 ?
CAPA procedure
Yes
A
Conduct inspection and testing to ensure the
Is meetingtooling
part made by production the meets the
customer
customer engineering specifications Re-plan pilot
engineering Identify root cause
production
specifications? and take action as per
No CAPA procedure
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
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ASWINI GROUP

Yes

No
Initiate new cycle of
Is sample approved
new product
by customer?
development process
Yes

Identify and conduct test for evaluating

packaging even if the packaging standard /
specification specified by the customer

Prepare production CP with the observation

gained from pilot production run (Production CP
is the logical extension of the pre-launch CP)

Review product and process validation Phase 4 CEO approval

(Phase 4) for management support

No
Stop the project,
Is reviewed and
record the reasons and
approved by CEO?
intimate to customer

Yes

Prepare Quality Planning sign – off, and use for product

development and Part Approval Process.

(Phase 5) Launch, Assessments, and Continual Improvement use

of standard quality tools such as PFMEA, SPC, PPAP,
and comprehensive controls plans for effectiveness.

Submit samples with PPAP documents and get approval from

customer with mass production plan.
6.2 Production Part Approval Process (PPAP)
Input Production Part Approval Process (PPAP) - Output
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
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Date: 22.03.2019

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ASWINI GROUP

Activity

New product Determine submission requirement with

development and customer Level of PPAP
changes in existing
Product/Process

Unless otherwise specified by customer the

default PPAP submission level is 3

Prepare and review applicable documents as

per PPAP Manual.

A
Forward PPAP documents with samples to
customer for approval

No Identify the reason

Is approved by and take action to
customer? submit revised PPAP

Yes

Collect the approved PPAP document from

customer and file it.

Notify applicable department of approval.

PPAP documents should be submitted during following situations

 A new part supplied

 Part modified by an engineering change
 Material change
 Process parameter Change (Pressure/Temp. etc)
 Process sequence / Layout Change
 Process equipment Change
 Relocation
 Supplier Change

PPAP documents to be submitted

 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
AQMS PROCEDURE
Date: 22.03.2019

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ASWINI GROUP

 Engineering change documents if any

 Process Flow Diagrams
 Process Failure Mode and Effects Analysis (PFMEA)
 Control Plan
 Initial Process capability studies
 Measurement System Analysis (MSA) studies
 Dimensional Results
 Material, Performance test result (If applicable)
 Checking Aids (to be retained by suppliers and to shown upon request)
 Part Submission Warrant
 Customer specific requirements if any.
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
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Date: 22.03.2019

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ASWINI GROUP

6.3 Product / Process Change Control

Input Product / Process Change Control - Activity Output

Receive the change request form from the

Internal complaints respective department / customer
Concessions and
Deviations
Any customer
complaints Understand the changes
Standardization
Manufacturing
requirements Analyse the factor involved
Continual
Improvement
Improve Establish the control factor
manufacturability
Productivity
improvement
Customer ECN
Yes
Intimate customer and
Is change related to get approval from
product / process? customer.

No

Implement the changes and record the change

details in the ECN and process change record

Update the changes in the relevant

documents within 10 working days

Communicate to respective department

through designated channel

Communicate to customer with samples

through PPAP and get approval incase of
product / process change.
 AUTOMOTIVE QUALITY MANAGEMENT SYSTEM Ref No.: QMP-10
Issue/Rev. No.: 2.0/1.0
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Date: 22.03.2019

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ASWINI GROUP

6.4 Control Plan

Input Control Plan- Activity Output

c
New product Collect data from process flow diagram and
development PFMEA.

Identify machine and equipment for all

processes.

Determine product characteristics and its

process parameters for each process.

Determine evaluation and checking method

for process / product parameters.

Identify sample size, product and process

control method for each process.

Prepare control plan and get customer Control Plan

approval if required.

Complaints from Review the control plan periodically for

customer / service improvements and update if required.

6.5 Special Characteristics

Identifies the special characteristics from customer drawings and specifications by CFT and communicates the same to the
relevant functions through control plan, PFMEA and SOP by the ASW symbol.

Identifies a special characteristic which will affect compliance with government regulations or safe Vehicle/Product Function
by the ASW safety/critical characteristics symbol <CC>

Identifies a special characteristic which will affect customer assembly and operation by the ASW significant characteristics
symbol <SC>

Controls on Critical Characteristics <CC>

Process capability : >1.67

Mistake Proofing : Prevention Poka-yoke
Operator Skills : Trained for <CC> and <SC>
Control Method : Online SPC (control chart) / Cpk Monitoring / 100% inspection
Measurement Technique : Gauge / Instrument as required by the customer
Controls on Significant Characteristics <SC>
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ASWINI GROUP

Process capability : >1.67

Mistake Proofing : Prevention / Detection Poka-yoke
Operator Skills : Trained for <CC> and <SC>
Control Method : Online SPC (control chart) / Cpk Monitoring/ 100% inspection
Measurement Technique : Gauge / Instruments as required by the customer

6.6 Identification of Statistical Tools

The statistical tools required for the processes to be identified at the time of APQP process and the same will be addressed
in the relevant control plan. Training of statistical tools will be given to the relevant person through human resource
department.

6.7 Multi Disciplinary Approach

Assign responsibilities to the cross functional team, Effective product quality planning requires the involvement of more than
just the quality department. The initial team includes representative from NPD, production, QA, purchase and supporting
process such as maintenance, stores and dispatch and laboratory if required.

7.0 Further Reference

7.1 Documented Information

As per List of Documented Information to be maintained – RD-ASW-01
As per List of Documented Information to be retained – RD-ASW-02