Volvo Apqp

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AdvancedProductQuality

Planning

Volvo 3P

APQP

APQP

Information for suppliers


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APQP information for suppliers

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Volvo 3P APQP

APQP

Contents

1 - What is APQP and its benefits ?

2 - When to start and how to share APQP planning and status with Volvo ?

3 - Where to find APQP information / templates ?

4 - What are the Volvo APQP specifics ?

5 - Conclusion: what to keep in mind


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1 - What is APQP and its benefits?


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Volvo 3P APQP APQP

APQP Definition and Objective accordingto AIAG

• Definition

”APQP is a guideline designed to produce a product quality plan

which will support the development of a product or service that

will satisfy the customer”

• Objective

”To facilitate communication with everyone involved to assure

that all required steps are completed on time”.


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Volvo 3P APQP APQP

Advanced Product Quality Planning

is supplier’s planningin compliance with AIAG reference manual

It is a VOLVO

requirement (incl.

RTS, PAA, PHR) as

specified in SQAM

Pre-requisite: supplier is trained to APQP

according to AIAG reference and its own

development process is in compliance with it


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Volvo 3P APQP APQP

What does APQP mean for Volvo?

• Supplier APQP team is responsible for performing the APQP and report toVolvo team during the APQP review meetings, using the APQP reviewcheck-list

• A very detailed supplier timing chart synchronised with Volvo project milestones

• A very detailed APQP check-list review aiming to identify and manage risks

• A management by project phases (not by activity as it was done in the past)

• A regular Volvo-supplier APQP follow-up meeting with formal reviews prior toVOLVO releases

• Additional 3 Volvo specific best practices (RTS, PAA, PHR)

→

A robust way of working cross-functionally between Volvo and supplier aiming todeliver a project at contracted QDCF


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Volvo 3P APQP APQP

APQP is supplier's planning that integrates VOLVO

inputs, constraints and deliverables and is synchronizedwith VOLVO project milestones

Examples of Volvo inputs:

• Technical requirements

• Time plan: part release dates, PPAP date, SP date…

• Prototype requirements

• Verification and validations performed by Volvo

….

APQP simplifiedprocess flow


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Volvo 3P APQP APQP

Volvo Objective for APQP

Have suppliers develop a relevant

plan for new part launch

Plan for

activities

Volvo - supplier interactions

Deliver to the plan

Successful activities on time !


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Volvo 3P APQP APQP

Benefits of APQP• Secures supplier project management is in place

• Ensures early planning takes place

• Establishes pro-active communication on both

Volvo and supplier side

• Identifies required changes early in the process in

order to mitigate risks and to reduce need for late

design and process changes

• Provides quality product on time and at lower cost

• Improves PPAP approved on time

• Reduces PPM levels at SOP

• Reduces field failures

Stronger & earlier supplier’s involvement in Projects

0

100

Supplier involvement

Room for Manoeuvre

IG VG CSG DG FDCG IG PPG EG

DeploymentConcept

Study

Detailed

Dvlpt

Final

Dvlpt

Industriali-

zationPre-study

CG FG LG RG

QDCF

CSG

DG FDCG IG PPG EG

DeploymentConcept

StudyDetailed

DvlptFinalDvlpt

IndustrializationPre-study

CG FG LG RG

Industrial launchCosts

Time

IG VG

Advanced Qual ity in Projects


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2 - When to start and how to share APQPplanning and status with Volvo ?


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Volvo 3P APQP APQP

Suppliers should provide the first APQP planning

with their answer to the Request for Quotation

10.4 Advanced Product Quality

Planning

(…)

The supplier is requested to build its

Plan of Product Realization according to

the AIAG APQP Manual.

(…)

The supplier is requested to submit with

its proposal … a preliminary APQP

plan …

Request For Quotation


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Volvo 3P APQP APQP

How to match with Volvo GDP? Development supplier

SQE coordinatescompletion of

VOLVO APQP

activities with the

Project Team

Supplier performs APQP activities under

its responsibility

Supplier

Product

Design

Supplier

Process

Design

Supplier

Process

Development

SupplierProduct &

Process

Validation

APQP

KICK-OFF

review

APQP

PRODUCT DESIGN

review

APQP

PROCESS DEVELOPMENT

review

APQP

LAUNCH

review

APQP

INDUSTRIALIZATION

review

Concept Study Detailed development Final development Industrialization

DG FDCG IG PPG RG

A

Release

B

Release

C

Release

P

Release

Supplier

selected

PPAP

Approved

Volvo

PPAP

amendment

VOLVO Project team performs

APQP activities under its

responsibility and consult Supplier

APQP deliverables

Volvo

PPAP

order


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Volvo 3P APQP APQP

How to match with Volvo GDP ? Production supplier

SQE coordinatescompletion of

VOLVO APQP

activities with the

Project Team

Supplier performs APQP activities under

its responsibility

Supplier

Process

Design

Supplier

Process

Development

SupplierProduct &

Process

Validation

Supplier

selected

APQP

KICK-OFF

review

APQP

PROCESS DEVELOPMENT

review

APQP

LAUNCH

review

APQP

INDUSTRIALIZATION

review

Concept Study Detailed development Final development Industrialization

DG FDCG IG PPG RG

A

Release

B

Release

C

Release

P

Release

PPAP

Approved

Volvo

PPAP

amendment

VOLVO Project team performs

APQP activities under its

responsibility and consult Supplier

APQP deliverables

Volvo

PPAP

order


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Volvo 3P APQP APQP

APQP planning: bad example

Updated:

2012

Jan Feb Mar Apr May J un Jul Aug Sep Oct Nov Dec Jan Febr Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Febr Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan

Projekt milestones

V3P APQP

Product Milesones

Process Checkpoints

Verification PPAP

P-drawing

MRD Blanks 10w28

MRD 10w36

Production 10w38

PSW 10w42

Allocatition request

Hub equipm Mfg

Personell BC

Logistic system Updating communication system

Material Handling

2011

Ref.V3P APQP

Plan Issue 1 date 10/8-09

2009

Project Plan

2010

03/11/09

P#3

10w2409w38

P#2

11w48

P#4

SoP

11w35

Packa in

10w47

PS

10w43

SPR

10w34

1 ST

10w25

IR

09w38

PDR

09w26

KO

09w26

P#0

Manufacturing & InstallOrders

09w40

10w34

Legend:

KO = APQP Kick-off

PDR = Product Design Review

PDR = Process Design ReviewIR = Industrialization Review

1 ST = 1:st part from Serial

SPR = Significant Production Run

LR = Launch Review

Training

LR

11w27

RFQDesi n

P

Significant prod. Run

10w42


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Volvo 3P APQP APQP

APQP review: the way to share APQP withVolvo

OBJECTIVES

•Detects any deviation,

assesses the risks and

assigns actions

•Gives visibility of the

progress to Volvo andsupplier teams

•Escalate the roadblocks

to project management /

line organization for

decision or action

DEFINITION

A formal meeting where Volvo

reviews supplier's APQP plan.

Volvo and supplier check that

the project at component level

is on track with respect to

deadlines and results.

ATTENDEES

Expected attendees :

•SQE

•Development (SIPD

leader, design engineer…)

•Buyer

… Manufacturing, Logistic,

Geometry, Laboratory…

•Supplier team (project

leader, engineering, quality,sales, manufacturing,

methods…)


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Volvo 3P APQP APQP

APQP reviews - Who Does What

SQE

Design

engineer

Buyer

Organizes the APQP reviews for

Key Components

Makes sure that all PROCESSdesign, verifications & validations

activities are integrated/completed :

timing and results

Ensures that the overall supplier

APQP plan is complete and

matches project milestones

Participates in APQP reviews for Key Components

Ensures that all PRODUCT design , verifications & validations activities are integrated/completed: timing and results

Participates in APQP reviews for

key components

Ensures APQP activities underhis responsibility are

integrated/completed:

timing and results

Supplier

project team

updates its

APQP plan and

evaluate the

project status:

Timing &Results


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Volvo 3P APQP APQP

APQP review reporting file

• APQP review reporting file is owned by the supplier

and totally shared with Volvo

• Contains

– contact directory

– co-signed time-plan – 1 check-list of questions per review

– 1 cover page for the summary. Project status and risks


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Volvo 3P APQP APQP

APQP review reporting file instruction


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3 – Where to find APQP informationand Volvo templates / guidelines


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Volvo 3P APQP APQP

Information, guidelines and templates• APQP manual from AIAG

http://www.aiag.org

• APQP in Volvo supplier portal

– APQP guideline for suppliers

– APQP review file – Generic APQP time plan

– APQP responsibility matrix

• Supplier Quality Assurance Manual


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4 - What are Volvo APQP specifics

(best practices)


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Volvo 3P APQP APQP

RTS - Review of Technical Specification

OBJECTIVES

•Make sure the supplier

understands early

enough all the technical

specifications of the

components to be supplied

to Volvo

•Supplier agrees on the

feasibility of these

specifications.

DEFINITION

A documented review of

technical specifications.

“Technical specifications”,

includes all the documentation

needed to specify and verify a

product (part version report orPVR, drawings, digital models,

technical requirements or TR,

standards, etc).

ATTENDEES


•Design engineer

•SQE

•Buyer

•Supplier team


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Volvo 3P APQP APQP

PAA - Product Application Agreement

OBJECTIVES

•The PAA ensures the

supplier agrees (by written

approval) that the product

he has designed will be

compatible with

environment constraintswhen installed and used in

all of the application

environments defined by

Volvo.

DEFINITION

The Product Application

Agreement (PAA) is a signed

agreement between Volvo and

a supplier.

ATTENDEES


•Design engineer

•Supplier team

•Buyer

Temperature

Vibration

Humidity

Electromagneticcompatibility

Proximity of

other parts

And more...


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Volvo 3P APQP APQP

PHR - Part Handling Review

OBJECTIVES

•The PHR ensures the

supplier agrees (by written

approval) on the

INDUSTRIAL

ENVIRONMENT &

PROCESS with which thepart he delivers is

assembled on

Trucks/Powertrain units.

DEFINITION

The Part Handling Review

(PHR) is a signed agreement

between Volvo and a supplier.

Physical visits to all VOLVO

plant areas shall be conducted

for PHR

ATTENDEES


•Volvo Manufacturing team

•Supplier team

•SQE

•Buyer

Parts

Delivery

(Inbound

logistic)

Truck /

Powertrain unit

delivery area

Storage

Assembly processTests

Tooling

And more...Handling Cleanliness

Rework


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5 – Conclusion: what to keep in mind


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Volvo 3P APQP APQP

APQP – What to keep in mind ?• APQP is owned by supplier and reported to Volvo,

using the APQP review file

• APQP plan takes into account the VOLVO constraints• Supplier provides his first APQP plan with the answer to the Request

for Quotation

• It is reviewed at least at each APQP review meeting

• APQP should contain enough details to be understandable

• Critical path and risk areas should be identified

• The plan must drive actions

• There will be problem: they must be fixed or escalated


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Volvo 3P APQP APQP

Glossary• APQP: Advanced Product Quality Planning

• DFMEA: Design – Failure Mode and Effect Analysis

• DVP&R: Design Validation Plan and Report

• GDP: Global Development Process

• GPS: Global Purchasing System

• MSA: Measurement System Analysis

• PAA: Product Application Agreement

• PFMEA: Process – Failure Mode and Effect Analysis• PHR: Part Handling review

• PPAP: Production Part Approval Process

• QDCF: Quality Delivery Cost Features

• RFQ: Request For Quotation

• RTS Review of Technical Specification

• SQE: Supplier Quality Engineer

Documents

Volvo Apqp