Doc No:-DVP/PR/01 Procedure for

Rev. No:- 00
Date:- 01.02.2020
APQP
Refer the Risk Assessment Document &
then follow these procedure :

1.0 PURPOSE:
To establish a procedure for advanced product quality planning for development of new products and
modifications in the existing products, to ensure that the products are developed as per the customer
requirements.
.
2.0 SCOPE:
This procedure is applicable to all automotive products that are developed by the company.

3.0 RESPONSIBILITY:
AGM Technology & New Product Development
.
4.0 PROCEDURE:
4.1 PROJECT INITIATION:

 Any new product development will be initiated based on Customer Enquiry

 In case of Products developed based on the customer’s enquiry, the enquiry review details, etc is carried out as
per the procedure for contract review.
 Product feasibility review is carried out by CFT. IF product is feasible to produce project Initiation approval is
taken.

4.2 PHASE I - PLAN & DEFINE THE PROGRAM:

 Based on the customer’s requirements, the CFT members prepares for Process design Timing Plan indicating
the activities to be carried out and target date.
 Based on the customer Specifications / Specific Requirements , the APQP input form shall be prepared by
collecting following information:
a) Past history such as warranty rejections, internal rejections, etc.
b) Things gone wrong and things gone right in similar product.
c) Customer requirements,
d) Benchmark data, etc.
 The CFT members collect all above information and review for the adequacy. If any information is missing,
same is planned and collected.
 Based on the collected information, the CFT members prepare preliminary process flow chart, preliminary
special characteristics.
 At the completion of above activities, a management review meeting shall be carried out to review the status of
the project and to identify any major concerns or any resources requirements. The minutes of meeting shall be
prepared and all the actions decided shall be implemented as per the minutes of meeting.
 Process Design timing plan prepared & periodically updated.

All the design & development stages and their progress is discussed in management review meeting.

PREPARED BY APPROVED BY

SR. EXECUTIVE - NPD AGM – TECHNOLOGY & NPD

 Doc No:-DVP/PR/01 Procedure for
Rev. No:- 00
Date:- 01.02.2020
APQP
4.3 PHASE II - PRODUCT DESIGN AND
DEVELOPMENT

4.3.1 Raw Material Requirement

 Materials settles on the source of raw material based on raw material specifications and other product
characteristics. The time required to obtain raw material is also noted on the Timing plan.

4.3.2 Requirement of New Equipment, Tooling and Facilities

 The Senior Executive – NPD. Identify any new equipment / tooling / facilities requirements, if any, and these
are identified in the Timing Plan, ensuring its capability and timely delivery. The progress of the
same is monitored by Senior Executive - NPD.

4.3.3 Identification of Special Product and Process Characteristics -

 Special product and process characteristics are identified by CFT if required other than those designated by the
customer. Most of the cases the customer designated symbols are used for identification, but if for the
same product (particularly the same characteristics) is identified as special characteristics by more than
one customer then it is particularly identified by the organization’s equivalent symbols.

4.3.4 Team Feasibility commitment

 Team feasibility commitment is performed by the CFT Members to assess the manufacturing capability of the
proposed design. All the CFT Members endorse the team feasibility commitment form as the commitment to
proceed further for product development. Where ever not feasible issues identified, action plan for the same is
prepared.

4.3.5 Management Support

 Project status review is made with CEO by AGM – NPD along with the CFT Members to review the status and
any concerns in the product development.

4.4 Phase III - MANUFACTURING PROCESS DESIGN AND DEVELOPMENT

Manufacturing Process Design Input:
CFT reviews design input requirements such as targets for productivity, process capability, cost and experience
of previous developments. Review details are recorded.

4.4.1 Packaging Standards and Specification

 The CFT reviews packaging standards & specifications, so as to ensure the product integrity at point of use. If
customer has specified packaging standards, the same are specified in the packaging Instructions
available with the concerned department.

4.4.2 Product / Process Quality System Review

 The CFT reviews the organization’s quality system documentation and if required adds controls or
makes procedural changes required to make the product. The MR assists in this activity and takes
appropriate action for timely completion of the project.
 Manufacturing Process Design Output:- output is verified against design input by CFT. Output includes-
Process Flow Chart, FMEA’s, Control Plan, Work instructions, Acceptance criteria, Etc.

4.4.3 Process Flow Chart

 The CFT prepares the proposed or existing process flow chart.

PREPARED BY APPROVED BY

SR. EXECUTIVE - NPD AGM – TECHNOLOGY & NPD

 Doc No:-DVP/PR/01 Procedure for
Rev. No:- 00
Date:- 01.02.2020
APQP
4.4.4 Floor Plan Layout
 CFT requests the concerned production supervisor to review the floor plan to determine the acceptability of
inspection points, acceptability of visual aids, interim repair stations, and storage areas to contain
defective material. All material flow is keyed to the process flow chart and control plan.

4.4.5 PFMEA
 Process FMEA is conducted as described in the Procedure for PFMEA.

4.4.6 Pre-Launch Control Plan:

 The CFT prepares all control plans on the basis of process flow chart and PFMEA.

4.4.7 Job Instructions (Standard Operating Procedures):

 The CFT develops Standard Operating Procedures that provide sufficient detail for all operating personnel
directly responsible for processes.
a) These instructions are developed from the following sources.
 FMEAs
 Control Plans
 Engg. Drawings, Performance Specifications, Material Specifications, Visual standards and Industry
standards.
 Process flow charts
 Floor plan layout
 Packaging standards
 Quality Plans
 Expertise and knowledge of the process & product.
 Handling requirements.
 Operating Personnel.

4.4.8 Measurement System Plan, Analysis and Evaluation:

 An Action Plan for implementing MSA is identified in the Timing plan. The CFT identifies
all instruments and gauges to be used to compare product characteristics with engineering
specifications.

4.4.9 Preliminary Process Capability Plan and Study -

 The CFT lists characteristics identified in the control plan that requires SPC. The Action plan for
implementing SPC is mentioned in the Timing Plan.

4.4.10 Management support

 Project status review is made by CFT Members to review the status and any concerns in the product
development.

4.5 PHASE IV - PRODUCT AND PROCESS VALIDATION

4.5.1 Production trial run

 Once the customer approves the sample, a production trial run is conducted using production tooling,
equipment, environment (including, production operators), facility and cycle time. The minimum quantity for the
production trial run is usually set by the customer and can be exceeded by the CFT.

PREPARED BY APPROVED BY

SR. EXECUTIVE - NPD AGM – TECHNOLOGY & NPD

Doc No:-DVP/PR/01 Procedure for
Rev. No:- 00
Date:-
APQP
4.5.4 01.02.2020
PPAP
 Production parts thus produced from production tools & process to meet Engg. standards are submitted to the
customer along with documents specified in “ PPAP” Procedure .

4.5.3 Production validation testing

 Production validation testing is carried out w.r.t engg. tests for validating the products made from production
tools and processes to engg. standards.

4.5.4 Packaging Evaluation

 Packed products are assessed for normal transportation damage and adverse environmental effects. This is
done as per agreement with the customer.

4.5.5 PRODUCTION CONTROL PLAN

 The CFT reviews the pre-launch control plan based on the results of the production trial run and the
customer’s feedback on the production parts submitted. The CFT then prepares a “production control plan”
to be followed during production.

4.5.6 QUALITY PLANNING SIGN OFF

 After preparing the production control plan, process flow diagram and job instructions, CFT co-ordinates
formal sign off using “Product Quality Planning Summary and sign off” format . Based on this, approval will
be given to production for Bulk production

4.6 PHASE V - FOLLOW UP

4.6.1 Feedback, Assessment and Corrective Action
 The CFT applies Continuous Improvement techniques and seeks ways to reduce the sources of variation.
Once the product is introduced into regular production, for any change , in customer need / production
equipment , PPAP procedure is followed. For any amendment in drawings / specifications / control plan / job
instructions, “Document and Data Control” procedure, is followed.
4.6 Project measures such as Cost estimation v/s actual, Activity planned v/s actual, etc. shall be monitored at
various stages. In case of planned activity, the same is monitored through the timing plan which will be
updated progressively, on completion of each activity.
4.7 Based on the above project measures, appropriate actions shall be decided during the project execution
phases.

5.0 PROCESS MEASUREMENTS :

Plan Vs. Actual development.

PREPARED BY APPROVED BY

SR. EXECUTIVE - NPD AGM – TECHNOLOGY & NPD