PPT – Supplier APQP Training Advanced Product Quality Planning PowerPoint presentation | free to view – id: 6a1044-ZDQyN

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Supplier APQP TrainingAdvanced Product Quality
Planning
GOAL FLAWLESS LAUNCH !
“Dana Confidential Information – Those having
access to this work may not copy it, use it or
disclose the information contained within this
work without the prior express written
authorization of Dana Corporation. Unauthorized
use may result in prosecution.”
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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

Supplier APQP TrainingAdvanced Product QualityPlanningGOAL FLAWLESS LAUNCH !”Dana Confidential Information – Those havingaccess to this work may not copy it, use it ordisclose the information contained within thiswork without the prior express writtenauthorization of Dana Corporation. Unauthorizeduse may result in prosecution.”Supplier APQP OverviewSupplier APQP OverviewDana Supplier Quality ManualSupplier APQPSupplier APQP Status ReportSupplier APQP ElementsSupplier APQP Status Report ElementsSupplier APQP Status Report ElementsSupplier APQP Status Report ElementsSupplier APQP Status Report ElementsSupplier APQP Status Report ElementsSupplier APQP Status Report ElementsSupplier APQP Status Report ElementsSupplier APQP Status Report ElementsObjective Evidence Required Elements 1 – 3Objective Evidence Required Elements 4 – 7Objective Evidence Required Elements 8 – 10Prototype Sample Inspection RequirementsAll prototype samples furnished by suppliersshall conform to the following requirements fortheir applicable Dana Product Group.Commercial Vehicle Light Vehicle DrivelineTechnologies – Each part is to be serialized on anon critical surface (consult with the applicableEngineering Group for non critical surfaceidentification). The preferred identification isPart Number and Consecutive Dash Number.(Example Part Number -1, -2, etc….). Aninspection report is to be furnished for eachserialized part for all critical/significantdimensions as designated on either the DanaDrawing or Engineering Specification. Atminimum, the inspection report shall include -date inspected, Inspector’s signature, partserial dash number, revision level, part name,purchase order number, part dimension/tolerance/actual dimension the Gage RR reports for allinspection tools utilized( for CMM submit a copyof the current Calibration Certificate).Prototype Sample Inspection RequirementsThe inspection report shall be in pdf file formatand named with the Dana Program, Part Number andDate. (Example Program Name_Part Number_Month-Day-Year.pdf). The inspection reportshall be shipped with the prototype samples.Prototype samples received without theaccompanying inspection report will be rejected.Any Metallurgical/Heat Treat/Physical Testresults available for the prototype parts shouldbe included with the inspection reportfurnished. Any additional inspectionrequirements, outside of that listed above, willbe delineated on the prototype quote request andlisted on the prototype purchase order. In allcases prototype samples that do not conform tothe Dana Drawing and/or Specifications shall notbe shipped prior to receipt of an approvedEngineering Change or Deviation. A copy of theapproval document shall be included with theprototype part shipment.Objective Evidence Required Elements11 – 12Objective Evidence Required Elements 13 – 15Objective Evidence Required Elements 16 – 19Objective Evidence Required Elements 20 – 23Additional Dana PPAP RequirementsSafe LaunchThe purpose of the Safe Launch Plan is to protectDana Facilities from receiving qualitynon-conformances during critical new productlaunch periods and validate the supplier’sProduction Control Plan during volume productionruns. It is in addition to all normal processinspections and evaluations outlined in theProduction Control Plan and is a post processing,off-line, separate and independent from thenormal manufacturing process check. Use of any inprocess inspection/containment stations requiresthe prior approval of Dana.The Safe Launch Plan shall be in effect for aminimum of 90 days or the first 5 supplierproduction runs, whichever is longer, from thestart of PPAP Approved part shipments to thereceiving Dana facility. If any discrepant partsare received by a Dana facility during the SafeLaunch period it shall be extended for atimeframe to be determined by the receiving Danafacility.Safe LaunchAny non-conformances discovered at a Danafacility during the Safe Launch period requireimmediate and irreversible corrective actionwithin 72 hours of notification. In addition, anynon-conformances discovered at a Dana facilityrequires supplier, or supplier designated,representation on site at the Dana facility toinitiate sorting and containment actions, backthrough their organization, within 24 hours.Safe LaunchThe Safe Launch Plan shall include 100evaluation of –All Dana designated Critical and/or SignificantCharacteristics (Variable)All Customer attachment( pass through)characteristics identified by Dana Engineering(Attribute)All Significant Characteristics to the processidentified by the supplier (Variable)Verification that the packaging and labelingconforms to the Supplier Packaging Specificationform approved by the receiving Dana facility.(Attribute)Safe LaunchData from safe launch inspections shall beforwarded to both the Dana Receiving PlantSupplierDevelopment_at_dana.com, for each productionlot shipped, so it is received prior to theproduction lot.Product shipped to Dana that has been evaluatedin the Safe Launch process shall be identified bymeans of a Green Sticker, attached to everyindividual carton, signed by the personaccountable to perform this function.Failure to implement a robust Safe LaunchProcess, containing these requirements as aminimum, will result in a Supplier being placedon Restricted Shipping 2 and other possibleconsequences.Customer Attachment PointsCustomer Attachment Points Customer AttachmentPoints will be communicated to suppliers bydesignation, ( ltCAPgt ), on Dana ProductDrawings. Customer Attachment Points requirePoke-A-Yoke at the source of manufacture. IfPoke-A-Yoke cannot be achieved an alternativecontrol plan method must be proposed by thesupplier and be approved by Dana.Questions