SAQP Elements Overview

8/2/2019 SAQP Elements Overview

1/38

Objectives

Supplier Development APQP

AQP Process

SAQE Responsibilities

Construction Of SAQP Workbook

Update & Review Procedure


2/38

XConcept

Design

Supplier

Selection

Feasibility

Manufacture

PPAP

Deliver


Product / Process

Maturity

SAQER

esponsibility

0 Defects ?

0 Defects ?

90 Days of production

0 Defects ?


3/38


PPAP APQP

Keep as Hard Copy in Folder or

Store on Computer

Backup or temporary storage of key

documents on Lotus notes database

Hard Copy in Folderor

Electronic copy on CD

Backup or temporary storage of key

documents on Lotus notes database


4/38


5/38

APQP


PPAP submission approval & master samples31

PPAP Interim30

SPSO (supplier process sign-off) - Capacity Verification29

Product Validation Testing28

Material certification27

AAR (appearance approval report)26

Dimensional Report25

Process capability study & Status24

Gauge functionality, certification, & R&R (reliability and repeatability)23

Production trial run22

IMDS data base acceptance21

Drawing Release for PPAP (Design Freeze)20

1st Off Tool Parts & dim report19

Packaging specifications & shipping plan18

Subcontractor PPAP status17

Pre-launch containment plan16

Control plan & control plan special characteristics15

Process FMEA14

Process flow chart & manufacturing floor plan13

Pre-production build plan & purchase order cover12

Tooling kick-off & purchase order cover11

Gauge design & feasibility10

Tool & equipment design & feasibility9

Design FMEA (failure mode & effects analysis)8

Capacity plan7

Team feasibility commitment6

DVP&R (design verification plan & report)5

Drawing & specification review & quality objectives4

AQP kick-off meeting & contacts list3

LON (letter of Nomination)2

SSOW (supplier statement of work) / DSKO (directed supplier kick off)1

Microsoft Excel

Worksheet


6/38


What is the purpose of the SAQP WorkbookTo provide a record of the current status for each element of the

AQP process, and to ensure that all outstanding issues have been

identified and allocated an owner for corrective action with

completion date.

It is not the Intention of the workbook to be the method tocommunicate issues to the SDT


7/38


Supplier

Develops

process

SupplierUpdates Workbook

SAQE Reviewsprocess and

checks workbook

Manages Issues

EPIC is updated with

StatusSDT Review

Keeps SDT

informed


8/38


1. S.S.O.W. / D.S.K.O. & Contacts List2. L.O.N. (Letter of Nomination)

Review SSOW paying particular attention to Program Timing

Project Scope Parts Matrix Rolls and responsibilities.

A list is created to identify all project responsible

contacts, including telephone numbers andlocation. Include:

Program MGR

Buyer Quality Logistics Engineering

What to KeepMeeting minutes

DSKO

Sample of SSOW

Sample of the Letter of Nomination

Note

The SSOW must be signed by both Supplier andJCA at beginning of project, and failure to comply

must be a RED issue.

Target

To ensure that the supplier

has the correct information

to develop the product to

achieve cost and quality

objectives over the product

life.


9/38


3. AQP Kick off Meeting

NoteAny changes from the agreed timing

must be done on the Issue / Action

section of the worksheet.

Target

Workbook is updated with

planned dates for each

element and these remain

fixed target for the

duration of the project.

What to Keep

SAQP report

SAQP Workbook

The APQP kick-off meeting allows supplier to interact with

the JCI launch team and opens the lines of communication

between the various functions.

The frequency of regular meetings is established.

The supplier is responsible at the APQP kick-off meeting to

either:1) Review with the launch team the names and dates

provided on a completed APQP timing summary.

2) Agree key dates, which are later referenced when

completing the form with names and dates.

The established target start and completion dates must never

be changed, but rather compared with the actual start andcompletion dates to assess the overall execution success of

the original plan.


10/38


11/38


What to Keep

DVP Report

FER_DVP

5. DVP&R(Design Verification Plan & Report)

The DVP&R is a summary of all development

testing required to ensure the product conforms to

defined customer needs and requirements. Testing

results are incorporated into the document as they

become available.

Target

All design defined material

and functional tests are

compliant


12/38


What to Keep

Feasibility report

FER_Feasibility

6. Team Feasibility Commitment

NoteFeasibility confirmation is needed

after each engineering change

Target

Supplier agrees requirements

can be manufactured to

required quality in serial

conditions to the planned

volume

All Important characteristics

to be measured and monitored

appropriately

It is the responsibility of supplier to assess the

feasibility of the proposed JCI design and/or product.

Supplier must confirm the product can be

manufactured as proposed and will meet the specifiedquality, cost, and delivery terms. The team feasibility

consensus is documented and includes a list of all

open issues.


13/38


7. Capacity Plan

Ensure the suppliers plan to achieve capacity is based

on the Peak volumes from SSOW and is achievable.

For Component suppliers.

Load the planned cycle times into the Master CapacityPlan. Ensure all other components on specified process

are also included.

For Assembly Suppliers

Complete OEE with planned cycle time

Target

To ensure that the supplier

has the capacity to produce

product at the quoted

values + 20% peak volume

What to Keep

1.A Master Capacity Plan

1.B OEE data sheet


14/38


15/38


9. Tool & Equipmentdesign & feasibility

NoteSAQE to monitor supplier

management of tool manufacture to

achieve tooling milestones

Target

Tooling manufactured is

designed to produce

expected quality parts for

product life.

What to Keep

Tool tracker or approved alternative

Review the suppliers plans for tooling and / or

equipment to ensure suitability for quality and

project life.

All SC & CC should have Poke Yoke included

in design to eliminate concerns.

For complex tooling or Equipment the Tooling

specialists should be involved in this review.


16/38


10. Gauge Design & Feasibility

NoteAll SC & CC must be gauged

preferably with variable result. On-

going SPC should be done off gauge.

Target

The gauges and fixtures

used to determine quality,

should be available for 1st

off tool parts.

SC & CC should be

measurable from the gauges

and used in the capability

studies.

What to Keep

Gauge plan

The gauge system review ensures necessary

characteristics are checked, and that calibration

requirements, gauge maintenance plans, and

financing are established. The approval to begin

gauge construction is issued at this meeting. All

customer and JCI owned gauges must be identified

as such.


17/38


11. Tooling KO & PO Cover

Ensure that All Tooling has been Kick off in

time to achieve PPAP, Purchase Order coverage

for all production tooling and equipment is

available.

A Timing plan is generated to review tool &

Equipment development.

For complex tooling, involvement of the SD

tooling team is required.

TargetTo ensure the tooling Is

kicked off in time to achieve

time plans

What to Keep

No specific document is used but a matrix ofall tooling and equipment with completion

dates would be required.

Tool Tracker


18/38


12. Pre Production Build plan

& PO cover TargetSupplier has a plan to

manufacture parts for key

build dates and understands

delivery requirements.

Purchase orders are in

place to cover all pre

series and testing parts

What to KeepNo specific document defined,

A plan of the pre-production build

requirements, including parts for testing mustbe communicated. Purchase order for the parts

should have been issued.

The project buyer should maintain a list of PO

cover


19/38


13. Process Flow Chart(Including floor plan)

Note SafetyAny part of process that has implications

on safety should be clearly identified.ie.

Welding Parameters

Material Hardening or Conditioning

!

A pictorial representation showing all of the steps of a

process. This must include detail of all points where

SC & CC are influenced and all material movement,

storage. Welding and surface treatment should beclearly identified

A floor plan with flow lines depicting material

movement should be included

TargetTo establish the

manufacturing route plan

and the movement and

storage that could have

impact on quality anddelivery.

This forms the structure to

develop the PFMEA

What to Keep

Process Flow Chart

Sample Floor plan

FER_MPFC


20/38


14. Process FMEA(including mistake proofing)

Note - SafetyAll processes that effect product safety

should be given special attention forcontrol and .

Welding

Hardening

Surface Treatment

!

A PFMEA should be conducted during product quality

planning and before beginning production. It is a

disciplined review and analysis of a new/revised

process and is conducted to anticipate, resolve, ormonitor potential process problems for a new/revised

product program. A PFMEA is a living document and

needs to be reviewed and updated as new failure

modes are discovered.

TargetA formal review of all current

quality issues on similar

products should be documented

and aligned with review of new

product.This should be reviewed with the

known quality outputs from

similar products in production

and the lessons learned from

them must be completed and

What to Keep

PFMEA

FER_PFMEA


21/38


15. Control plan

NoteControl plan must be in English or a

copy maintained in English.Specific attention should be made to

the ongoing control of SC & CC

!

The production control plan is a written

description of the systems for controlling parts

and processes. Particular attention should be

given to the control of special characteristics

The production control plan is a living

document and should be updated during the

development of the project from Prototype

Pre launch and production to reflect the

addition/deletion of controls based on

experience gained by producing parts.

(Approval from JCA is required.)

TargetIn conjunction with the

PFMEA all the key RPN issues

have controls applied to

ensure the failure does not

appear in production.

This includes all measurement

equipment and frequency of

checks likely to detect

failure.

What to KeepControl Plan

FER_Control plan


22/38


16. Pre-Launch Containment PlanTarget0 defects during pre-launch

period

What to KeepMeasurement reports

Inspection reports

The pre-launch containment plan, is required to prevent

defect parts being sent to the customer during a period

where the process knowledge is developing. It contains

all information necessary to ensure customer

understanding of the quality delivered product.

This should include, but is not limited to:

Dimensional validation of delivered parts, including key

measurements including SCs & CCs

All deliveries are approved by a person who validates all

quality checks have been performed before despatch.

NoteSpecial Attention is needed for all

Welding and heat treatment

processes

!


23/38


17. Subcontractor PPAP StatusTargetAll parts using in supplied

assembly are validated to

the same level as the

supplied part

What to Keep

Matrix of all sub-component PPAP Status

A key supplier launch responsibility is the

development and monitoring of sub-supplier quality

systems. To ensure the timely PPAP submission of

sub-contractor components this task is tracked in

program timing. The sub-contractor PPAP may alsobe reviewed in the run at rate/process sign off.

Supplier must track PPAP documentation for each

purchased component:

NoteAll SC & CC, Surface treatment,

Heat treatment, welding orconditioning must be traceable

through sub component approval.

!


24/38


18. Packaging Specifications

& Shipping Plan

Note

TargetAn agreed method of packaging

to ensure all products are

received in perfect condition

What to KeepPackaging Specifications form

The product quality planning team ensures that

individual product packaging is designed, tested and

proven out. JCI packaging standards or generic

packaging requirements are to be used whereappropriate. In all cases, the packaging must ensure

that the product performance, appearance and

characteristics are not adversely affected by

handling and/or shipping. Packaging must be

compatible with all material handling equipment.

Product must be shipped via a JCI approved carrier.


25/38


19. 1st Off Tool parts & Dim report,

NoteThe dimensional report can be from

CMM against CAD for this element

Once tooling is completed it is key to ensure the

tooling or equipment can produce a correct part, the

manufacturer must provide data to confirm the part

produced from the tooling is dimensionally correct

before delivery.

TargetTo ensure tool or process

manufactures a part to the

drawing at the earliest

opportunity.

What to Keep

Dimensional report


26/38


20. Drawing Release for PPAPDesign Freeze

NoteAny changes not agreed in the PPAP

release cannot be implemented until

90 days after Job 1

TargetThe drawing released must be

compatible for the part being

PPAPd.

No changes to the design are

acceptable from this point

unless

with specific demand from

Customer with declared timing

implications

Or

Changes are needed to correctfunctionality.

What to KeepCopy of drawing to be included in PPAP

Feasibility form

The drawing released must be compatible for the

part being PPAPd.

there has to be agreement with program manager

what is the eng. level for PPAP - than thatengineering level has to be released via EPIC

S i A Q


27/38


21. IMDS Data Base Acceptance

The supplier shall provide evidence that the

Material/Substance Composition reporting that is

required by the customer has been completed for

the part and that the reported data complies with all

customer-specific requirements.

TargetTo ensure that the

component data is accepted

by JCA in the data base.

The IMDS registration

number is recorded on the

PSW

The Number should also be

Recorded on the Workbook

in the comments for that

element

What to Keep

Copy of IMDS acceptance reportSample screen shot

NoteThe element is only complete when

the part is accepted on the data base

S li D l t APQP


28/38


22. Production Trial Run

NoteData on production can be used for

initial understanding of capacity

For production parts, product for PPAP shall be taken

from a significant production run. This significant

production run shall be from one hour to eight hours of

production, and with the specific production quantity

to total a minimum of 300 consecutive parts, unless

otherwise specified by the authorized customerrepresentative. This significant production run shall be

conducted at the production site, at the production rate

(see Glossary) using the production tooling, production

gauging, production process, production materials, and

production operators. Parts from each uniqueproduction process, e.g., duplicate assembly line and/or

work cell, each position of a multiple cavity die,

mould, tool or pattern, shall be measured and

representative parts tested

TargetProcess runs under serial

production conditions to

approved control plan

What to Keep

Components for ISIR & Capability

Inspection reports

S li D l t APQP


29/38


23. Gauge Functionality, Certification,R&R (Reliability And Repeatability

NoteALL gauges should be measured

using R&R including attributegauges

Where special gauges, fixtures, or test equipment

are required per the

control plan, verify gauge repeatability andreproducibility (GR&R) and proper usage.

TargetIt is important to ensure

that the gauge is detecting

error in the part not

variation error in how the

gauge is used to measure thepart.

What to Keep

R&R Study results

S li D l t APQP


30/38


24. Process Capability Study

NoteSPC is a long term process and

needs to be continued on keycharacteristics

!

The purpose of this requirement is to determine if

the production process is likely to produce product

that will meet the customers requirements. The

initial process study is focused on variables not

attribute data. Initial capability must achieve a Cpkof 1.67 minimum with no special causes evident in

control chart

NOTE Unless approved in advance by JCA ,

attribute data is not acceptable for PPAP

submissions

Target

Validation that each of the

SC & CC applied to

dimensions is capable of

achieving its intendedtolerance for product life

What to Keep

Control chart (Analysed for special causes)

Histograms for distribution

List of all SC and Cpk PIPC (from CRT

agreement)



31/38


25. Dimensional Report

NoteThe dimensional results for all 6

parts must be recorded separately

The supplier shall provide evidence that dimensional

verifications required by the design record and the

Control Plan have been completed and results indicate

compliance with specified requirements. The supplier

shall have dimensional results on 6 parts for each

unique manufacturing process, e.g., cells or

production lines and all cavities, moulds, patterns or

dies (see 2.2.18). The organization shall record, with

the actual results: all dimensions (except reference

dimensions), characteristics, and specifications as

noted on the design record and Control Plan.

TargetTo confirm that the

produced part conforms to

the drawing.

6 parts are measured and

the master samples should

be taken from these.

Remaining parts to be

available for testing.

What to KeepDimensional report

Material Test report



32/38


26. AAR

(Appearance Approval Report)

NoteEach part and colour should be

measured and the values on AARmust be within design tolerances or

Master plaque whichever is agreed

A separate Appearance Approval Report (AAR)

shall be completed for each part or series of parts

if the product/part has appearance requirements onthe design record.

TargetCustomer approval of all

defined surface parts for

PPAP submission

What to Keep

AARSample



33/38


27. Material Certification

NoteEnsure all planned material types

conform to design record includingregional variations before testing is

completed.

In addition to drawings and performance

specifications, material specifications should be

reviewed for Special Characteristics relating to

physical properties, performance, environmental,

handling, and storage requirements. Thesecharacteristics should also be included in the control

plan.

The supplier shall also submit a completed Design

Verification Plan and Report that summarizes

appropriate performance and functional test results.

TargetValidation that the material

used performs to the

expectation of the design

What to Keep

Material Report



34/38


28. Product Validation TestingTargetComponent passes all test

capability and dimensional

requirements

Process achieves all

throughput and delivery

requirements

What to Keep

Records of compliance not retained in PPAP

PVT assures compliance to all JCI and/or

Customer requirements and is required for all

new or modified parts. The PV test samples

must be taken from a 300 piece production

simulated run incorporating production toolsand processes. PV testing may only begin

after all parts from external sub -suppliers

have PPAP approval, or have deviations

documented.



35/38


29. SPSO

(Supplier Process Sign-Off)

NoteSPC is done in a controlled way to

an agreed plan.There is a reaction plan available for

adverse signals

!

TargetValidate the process can

produce 0 defect

production and planned

production speed .

All checking and control

documentation is in place

and operators are trained.

The supplier process sign-off (SPSO) verifies the

effective implementation of supplier quality

systems and evaluates suppliers manufacturing

readiness. The SPSO is initiated prior to the

supplier part submission to JCI. The advanced

quality engineer (or designate) will schedule and

lead the SPSO using the supplier process sign-off

form.

What to Keep

SPSO report WW-PLUS-FR-04-43



36/38


30. PPAP InterimTargetThe target should always be

to not need Interim PPAP but

if there is no alternative,

then a mechanism must be

introduced to ensure thatthe issues are followed up

and full

PPAP introduced.

What to KeepDA

Corrective action plan

With agreement of Customer an Interim PPAP can be

signed with DA, but:

Each DA has to be signed by Program manager

For each DA there has to be plan for elimination of

the deviationDA number has to be mentioned on PSW

After DA is eliminated, a new PSW to be signed

NoteIssues like missing released drawings,

should not be covered by DA and if S-AQE

is asked to sign PPAP with those issues, S-

AQE should consult this with SDM before

PPAP signing off.

!



37/38


31. PPAP Submission Approval

& Master Samples

NoteAn organization supplying standard catalogue

production or service parts shall comply withPPAP unless formally waived by theauthorized customer representative.

PPAP is developed to AIAG 4th Edition

PPAPs purpose continues to be to provide the

evidence that all customer engineering design

record and specification requirements areproperly understood by the organization and that

the manufacturing process has the potential to

produce product consistently meeting these

requirements during an actual production run at

the quoted production rate.

TargetThe purpose of PPAP is to

determine if all customer engineering

design record and specification

requirements are properly understood

by the organization and that the

manufacturing process has thepotential to produce product

consistently meeting these

requirements during an actual

production run at the quoted

production rate.

What to Keep

JCA Standard is submission level 3 refer to PPAP

presentation for retention requirements



38/38


Task 1From the provided documents create an AQP folder

Task 2Create a SAQP Workbook from the folder and set status and

comments for each element

Documents

SAQP Elements Overview