APQP Elements: 1 Customer Order
APQP Elements: 1 Customer Order
APQP Elements: 1 Customer Order
APQP Elements
Note:
The most significant changes compared with the previous version of 2013 are displayed in green
text below.
The aims, expectations and requirements associated with documenting the individual elements of
the APQP Status Report (see internet marketplace SupplyOn Project Management at
www.SupplyOn.com or QAA / S 296001-1 - Advanced Product Quality Planning, Appendix 3) are
described below:
1 Customer order
Aim:
Formal placing of an order by the customer so that investments can be effected on schedule by
the supplier.
Expectations:
The customer selects a supplier and informs the supplier of the decision.
Documentation with supplier:
Nomination Letter
Individual order indicating Risk Level (RL) for Advanced Product Quality Planning (APQP) and
the submission level for the sampling operation
Delivery schedule
Submission to customer:
Status in APQP Status Report
2 Customer specifications
Customer specifications include, for example, the design briefs, drawings or specifications which
are required at the start of a project.
Technical and project-related data
Aim:
To avoid misunderstandings by using clear specifications.
Expectations:
The supplier must be familiar with the requirements of the product / project, e.g.
requirements/regulations of the (end) customer which are relevant to the supplier
installation situation
ambient conditions
functional performance requirements
dimensions
weight
material
reliability (life)
guarantee objectives
quality objectives for incoming parts (ppm rating, defect levels and rejection quotas)
capacity data or volumes
S 296001-1 Appendix 2
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milestones
checking the program status
final definition of the design (Design Freeze)
prototype parts
pre-production
initial volume production samples
3 Craftsmanship (appearance)
Aim:
To define characteristics relating to appearance, texture, handling ability and acoustics.
Expectations:
The supplier should be familiar with and meet the requirements that relate to the abovementioned characteristics.
In order that the characteristics can be checked, characteristics catalogues and reference
samples etc. should be made available and agreed with the customer.
Documentation:
Characteristics catalogues and reference samples
Submission to customer:
Status in APQP Status Report
S 296001-1 Appendix 2
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4 Design FMEA
Only applicable to suppliers with personal responsibility for product development.
A Design FMEA is a systematic procedure used to ensure that potential development and design
defects and their respective causes have been taken into account and have been countered by
preventive measures within a technical cross-functional team.
The Design FMEA must cover all functions of the product and must take into account experiences
and concerns.
Aim:
To prevent defects during product development.
Expectations:
The severity levels from the customers FMEA are taken into account
Problems relating to product layout are solved in good time so that all sampling and volume
production dates can be observed.
Checks can be made on progress in respect of the Design Verification Plan.
Unforeseen potential defect modes which occur at the design review stage must be incorporated into the Design FMEA and the layout criteria modified in agreement with the customer.
Checks must be made on potential for improvement as regards product reliability and
manufacturing costs.
Checks must be made on progress in terms of achieving goals relating to reliability, quality,
costs and planning.
Influencing defect modes are described and assessed and, where necessary, corrective
measures are introduced and monitored by the persons responsible.
Documentation with supplier:
Design FMEA
Submission to customer:
Status in APQP Status Report
Cover sheet to Design FMEA including participants and issue level
5 Design Review
Aim:
To prevent misunderstandings and problems.
To monitor the progress of measures and to ensure that objectives are met.
Expectations:
Problems relating to product layout are solved in good time so that all sampling and volume
production dates can be observed.
Checks can be made on progress in respect of the Design Verification Plan.
Unforeseen potential defect modes which occur at the design review stage must be
incorporated into the Design FMEA and the layout criteria modified in agreement with the
customer.
Checks on potential for improvement as regards product reliability and manufacturing costs
Checks must be made on progress in terms of achieving goals relating to reliability, quality,
costs and planning.
Documentation with supplier:
Meeting reports prepared by the supplier or the customer
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Submission to customer:
Status in APQP Status Report
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14 Process FMEA
A Process FMEA is a systematic procedure used to ensure that potential production defects and
their respective causes have been taken into account and have been countered by preventive
measures within a technical cross-functional team.
The Process FMEA, e.g. to VDA volume 4 or similar, must cover all production and inspection
stages and must take into account experiences and previous concerns.
Aim:
To prevent defects during process development.
Expectations:
All production and inspection stages are listed and analysed.
Potential defect modes are described and evaluated and, where necessary, corrective
measures are introduced and monitored by the persons responsible.
Significant numbers are coordinated with the customer.
Documentation with supplier:
Process FMEA
Action plan for high risk priority number (RPN)
Submission to customer:
Status in APQP Status Report
Cover sheet to Process FMEA including participants and issue level
Pareto analysis of risk priority numbers (top 20 of RPN)
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pre-launch,
Expectations:
The type and scope of the inspections and the corresponding inspection equipment for prelaunch are defined and agreed with the customer.
Reaction plans are defined for handling discrepancies.
All "special characteristics are included.
Documentation with supplier:
Pre-Launch Control Plan
Submission to customer:
Status in APQP Status Report
Pre-Launch Control Plan
17 Process instructions
All instructions for production personnel, e.g. production plans, work instructions and inspection
instructions, maintenance plans, defect catalogues, process parameters.
Aim:
To ensure quality and quantity.
Expectations:
Easily understood (available in the national language of the respective production site) and
accessible instructions, at the workplace, to ensure that procedures are followed and
requirements regarding the process or the product are implemented.
Descriptions are given of the procedures involved in controlling defective products.
All employees must have been trained or instructed in the tasks they are to perform. Proof of
training must be kept and expertise regulated.
Documentation with supplier:
Process instructions
Proof of training
Submission to customer:
Status in APQP Status Report
S 296001-1 Appendix 2
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Logistics concept
Aim:
To ensure delivery capability in agreement with the relevant customer contact.
Expectations:
Call-off system, e.g. Web-EDI
Definition of transport routes
Customs arrangements (where applicable)
Inventory, e.g. consignment warehouse, safety stock
Compliance with Schaeffler Logistics Guideline
(see www. schaeffler.com/supplier/logistics/sets of rules)
Documentation with supplier:
Logistics agreement with the customer, minimum inventory planning
Submission to customer:
Status in APQP Status Report
S 296001-1 Appendix 2
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