APQP Quality Planning in ISO 9000/ QS-9000 or ISO/ TS 16949 or ..... . Heribert Nuhn, QMS APQP Quality Planning in ISO 9000/ QS-9000 or ISO/ TS 16949 or ..... 01.12.2018 Q_Planning_QS-9000_E

QM System Documentation . Heribert Nuhn, QMS QM System Documentation Level 1: Approach & Responsibility Quality Manual Level 2: Who, What, When Procedures Level 3: How Job Instructions Level 4: Quality Record/ Evidence Other Documentation 01.12.2018 Q_Planning_QS-9000_E

APQP - Elemente Definition and Fundamentals . Heribert Nuhn, QMS APQP - Elemente Definition and Fundamentals APQP is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer. The goal is to facilitate communication with everyone involved to assure that all required steps are completed on time. 01.12.2018 Q_Planning_QS-9000_E

APQP - Elemente Definition and Fundamentals . Heribert Nuhn, QMS APQP - Elemente Definition and Fundamentals direct resources to the new project promote early identification of required changes avoid late changes provide quality product on time lowest cost 01.12.2018 Q_Planning_QS-9000_E

APQP Fundamentals of APQP organize the team define the scope . Heribert Nuhn, QMS APQP Fundamentals of APQP organize the team define the scope establish team-to-team communication provide training define customer and supplier involvement simultaneous engineering Control Plans (all phases) concern resolution product quality timing plan Product Quality Planning Timing Chart 01.12.2018 Q_Planning_QS-9000_E

APQP Timing Chart 01.12.2018 Q_Planning_QS-9000_E Concept Initiation/ . Heribert Nuhn, QMS APQP Timing Chart Concept Initiation/ Approval Program Approval Prototype Pilot Launch Planning Planning Product Design & Development Process Design & Development Product & Process Validation Production Feedback Assessment and Corrective Action 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Planning: Input voice of the customer business plan . Heribert Nuhn, QMS APQP - Elements Planning: Input voice of the customer business plan product/ process benchmark data craftmanship (Ford) product/ process assumptions product reliability studies customer input: QS-9000 Section II & Appendix 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Planning: Output Product Design & Development: Input . Heribert Nuhn, QMS APQP - Elements Planning: Output Product Design & Development: Input design goals reliability and quality goals preliminary bill of material preliminary process flow chart 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Planning: Output Product Design & Development: Input . Heribert Nuhn, QMS APQP - Elements Planning: Output Product Design & Development: Input preliminary listing of special product and process characterisics product assurance plan management (sign-off and) support sourcing decision (Ford) customer input requirements (Ford) 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Product Design & Development: Output . Heribert Nuhn, QMS APQP - Elements Product Design & Development: Output Process Design & Development: Input Design Failure Mode & Effects Analysis (D-FMEA) Design for manufacturing and assembly Design Verification (Plan and Sign-Off Report) DVP&SOR Design Reviews 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Product Design & Development: Output . Heribert Nuhn, QMS APQP - Elements Product Design & Development: Output Process Design & Development: Input Prototyp Build Control Plan engineering drawings (including math. data) engineering specifications material specifications drawing and specification changes 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Product Design & Development: Output . Heribert Nuhn, QMS APQP - Elements Product Design & Development: Output Process Design & Development: Input new: equipment, tooling and facilities requirements logistics (Ford) special product and process characteristics gages/ testing equipment requirements supplier APQP: requirements & involvement (Ford) Team Feasibility Commitment & Mgmt. Support 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Process Design & Development: Output . Heribert Nuhn, QMS APQP - Elements Process Design & Development: Output Product & Process Validation: Input packaging standards product/ process Quality System Review Process Flow Chart Floor Plan Layout (special) characteristics matrix Process Failure Mode and Effects Analysis (P-FMEA) 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Process Design & Development: Output . Heribert Nuhn, QMS APQP - Elements Process Design & Development: Output Product & Process Validation: Input Pre-Launch Control Plan process instuctions measurements system analysis plan preliminary process capability study plan packaging specifications management support 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Product & Process Validation: Output . Heribert Nuhn, QMS APQP - Elements Product & Process Validation: Output Feedback, Assessment & Corr. Action: Input production trial run measurement systems evaluation preliminary process capability study production part approval (process (=> PPAP/ PSW)) production validation testing 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Product & Process Validation: Output . Heribert Nuhn, QMS APQP - Elements Product & Process Validation: Output Feedback, Assessment & Corr. Action: Input packaging evaluation Production Control Plan quality planning sign-off management support PSW Part Delivery at IPD/ MRD (Ford) 01.12.2018 Q_Planning_QS-9000_E

APQP - Elements Feedback, Assessment & Corrective Action: Output . Heribert Nuhn, QMS APQP - Elements Feedback, Assessment & Corrective Action: Output Input and Benefit for: Production reduced variation customer satisfaction delivery and service 01.12.2018 Q_Planning_QS-9000_E

PPAP Definition and Fundamentals . Heribert Nuhn, QMS PPAP Definition and Fundamentals PPAP defines generic requirements for production part approval, including production and bulk materials. The purpose of PPAP is to determine if all customer engineering design record and specific requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. 01.12.2018 Q_Planning_QS-9000_E

PPAP: Section I I. 1 General I. 2 PPAP Process Requirements . Heribert Nuhn, QMS PPAP: Section I I. 1 General I. 2 PPAP Process Requirements I. 3 Customer Notification and Submission Requirements I. 4 Submission To Customer - Levels Of Evidence I. 5 Part Submission Status I. 6 Record Retention 01.12.2018 Q_Planning_QS-9000_E

. Heribert Nuhn, QMS PPAP: Section II II. 1 DaimlerChrysler Corporation-Specific Instructions II. 2 Ford-Specific Instructions II. 3 General-Motors-Specific Instructions II. 4 Truck OEM-Specific Instructions Appendices A-E: Forms Appendix F: Bulk Material - Specific Requirements Appendix D: Tire Industry - Specific Requirements Glossary 01.12.2018 Q_Planning_QS-9000_E

Applicability internal and external suppliers . Heribert Nuhn, QMS Applicability internal and external suppliers bulk material (like gas, liquid, chemicals if requested) production material (customer production part number) production and service parts standard catalogue production and service parts customer can waive PPAP requirements 01.12.2018 Q_Planning_QS-9000_E

. Heribert Nuhn, QMS I. 1 General obtain full approval from the customer product approval activity for: new part or product correction of a discrepancy modified product by an engineering change to: design records, specifications, materials any situations required by Section I. 3 01.12.2018 Q_Planning_QS-9000_E

I. 4 Levels of Evidence Submission To Customer Level 1: PSW (and AAR) . Heribert Nuhn, QMS I. 4 Levels of Evidence Submission To Customer Level 1: PSW (and AAR) Level 2: PSW, product samples, limited supporting data Level 3: PSW, product samples, complete supporting data Level 4: PSW, requirements as defined by customer Level 5: PSW, product samples, complete supporting data for review at suppliers manufacturing location 01.12.2018 Q_Planning_QS-9000_E

I. 4 Levels of Evidence Submission To Customer . Heribert Nuhn, QMS I. 4 Levels of Evidence Submission To Customer Level 3 is default for all submissions Level 1 is default for bulk material customer product approval activity will identify submission level for each part or product number and manufacturing location 01.12.2018 Q_Planning_QS-9000_E

I. 4.1 Retention Table Submission Level . Heribert Nuhn, QMS I. 4.1 Retention Table Submission Level Requirement Level 1 Level 2 Level 3 Level 4 Level 5 1. Design Records of Saleable Product R S S * R 4. Design FMEA R R S * R 6. Process FMEA R R S * R 13. Part Submission Warrant (PSW) S S S S R 16. Sample Product R S S * R 17. Master Sample R R R * R 19. Records of Compliance R R S * R With Customer-Specific Req. ( see complete listing in Appendix: Retention/ Submission Requirements Table ) S: submit documents to customer and retain a copy R: retain documents and make readily available upon request * : retain documents and submit to customer upon request 01.12.2018 Q_Planning_QS-9000_E