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Process Training - Supplier

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1 Process Training - Supplier
Project Conference 2009 2/17/2018 APQP – Advanced Product Quality Planning– Supplier Quality Process Training - Supplier Revised: January 5, 2015 Revision Number: 1 Polaris CONFIDENTIAL © 2010 Microsoft Corporation. All rights reserved. Microsoft, Windows, Windows Vista and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries. The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation. MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.

2 Welcome Welcome to the Advanced Product Quality Planning (APQP) Polaris Supplier Training Module. This module will allow you to better understand the requirements, expectations and process for delivering new products and/or parts to your customer with great success through the use of APQP. A P Q P Welcome! Polaris CONFIDENTIAL

3 Agenda APQP: Polaris Internal Training Module Learning Objectives
The Process Flow – the When and How The What, When, Who of APQP Training Content Tools and References Demo / Example Learning Objectives Recap FAQ Thank you! APQP: Polaris Internal Training Module Polaris CONFIDENTIAL

4 Learning Objectives At the end of this training, participants will be able to: Understand the overall process of APQP and when you are required to utilize the APQP process. The importance of a standardized method for APQP Guidelines for APQP How to use the APQP process. Focus on the objectives and ask questions throughout!! Polaris CONFIDENTIAL

5 Supplier Qualification Quality Event Resolution
Process Overview Critical Process Steps: This will be your guide in the presentation to give you an understanding of APQP topic and its benefits to you. Process Usage: High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review The Quality Lifecycle Management process is a process to ensure product quality assurance. You are here! Supplier Qualification PDP PPAP Supplier Performance Monitoring Control Improvement …… ……. Serial Production ……… Maturity Volume Ramp…. SOP PPAP …..APQP…… Supplier Selection EOL Supplier On-Boarding APQP Safe Launch Product Assurance Quality Event Resolution APQP is integrated with PDP (Polaris Development Process) Polaris CONFIDENTIAL

6 What is APQP? Advanced Product Quality Planning is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer’s needs and that failure modes are identified and mitigated early in development process Hard to Find Easy to Fix Failures Easy to Find Hard to Fix Failures

7 Guiding Principles The AIAG Advanced Product Quality Planning (APQP) and Control Plan Reference Manual [available at aiag.org] provides the general guidelines for ensuring that APQP is implemented in accordance with the requirements of the customer. The APQP spreadsheet used by Polaris includes the corresponding page number referencing each of the APQP steps for quick orientation

8 Why do APQP? A Advanced – start early, with concepts, drive collaboration from onset Product – focus on the product and the customer needs/requirements Quality – Get it right the first time, efficiently and every time, build quality in from concept Planning – Collaboration will drive a robust plan and a superior product launch P Q P

9 Who has responsibility within APQP?
Project Lead SQE – Assigns key dates (gates) and measures progress of entire program SQE’s – Facilitate APQP activities with suppliers, help to pull in PII resources, coordinate joint activities, keep project on task, support the supplier Plant Quality – Support suppliers, SQE’s, design engineers, etc through the course of APQP. Play pivotal role in customer needs and PPAP approval. Engineering – Execute assigned APQP activities, participate in design reviews, FMEA reviews, etc and support supplier for DFM activities Purchasing – Assist in APQP activities, support entire team and collaborate as necessary to ensure tasks are completed on time and accurately Supplier – Execute APQP activities, on time, thoroughly to prepare for a successful launch Execute to the plan

10 Part Risk Management Funnel
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review What Parts get APQP? BOM Parts New/Revised Parts Group 1, Group 2 Risk Parts Critical Parts APQP Parts Identify parts that are Safety- or Performance-Critical All Group 1 Risk Parts + Group 2 Parts that have new/problem supplier or historically problem part Highest risk critical parts Parts follow detailed supplier selection process. Risk communicated through heat map Part status managed and communicated through APQP Plan/Report Card Sourced Product Risk Analysis Project-Level Heat Map Part Risk Management Funnel Narrow full BOM to critical few parts with greatest risk to program

11 Supplier Risk Management Framework
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review Supplier Risk Management Framework Maintain throughout program Gate 1 CSR Gate 2 SOP Sourced Product Risk Analysis Heat Maps  APQP Plan

12 APQP Level Selection 63 Total Potential APQP Steps to Select
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review APQP Level Selection Level M – Manual 63 Total Potential APQP Steps to Select Level 1 – Low Risk 21 Mandatory APQP Steps Selected Level 2 – Medium Risk 29 Mandatory APQP Steps Selected Level 3 – High Risk 39 Mandatory APQP Steps Selected Level M is for manually selecting requirements based on project, part and/or supplier need Levels 1 – 3 are minimum APQP requirements as determined by Polaris, other value added APQP steps may be selected by the Supplier/Polaris cross functional teams

13 How the Key Dates are Selected
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review How the Key Dates are Selected Key dates are selected based off of PDP gate milestones and key build dates and assigned by the lead PII SQE Gate 2 V (Validation) Build PDP Design Revew PI (Production Intent) Build PV (Process Verification) Build Gate 3 SOP All dates between milestone dates are to be agreed upon by Polaris and Supplier and must meet key Gate dates. Key Dates are selected by Polaris – Activity Dates selected by team

14 High Level Part Risk Identified pre G2
Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review Supplier APQP Kickoff The Kickoff meeting is one of the most important events for a supplier working on APQP. Objectives of Kickoff: Establish Part List Establish Core Team Communicate key dates and JOINTLY select activity dates Agree upon a review / submittal cadence Determine escalation path if project goes off track Kickoff meeting is critical to project success

15 Fulfilling the Requirements
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review Fulfilling the Requirements Be thorough in your document review before submitting Add completion percentage to cover sheet: when 1.0 is entered, SQE will review that element and sign off or send back comments/feedback Add non-data intensive elements to the workbook tabs For data intensive elements, add cover sheet to tab and send actual documents to SQE via

16 How to use the APQP spreadsheet
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review How to use the APQP spreadsheet

17 How to use the APQP spreadsheet

18 How to use the APQP spreadsheet

19 How to use the APQP spreadsheet

20 How to use the APQP spreadsheet
The tabs at the bottom of the workbook are hyperlinked to the steps on the APQP sheet Information on APQP and sometimes sample forms are located on these tabs The tabs should also be used to convey information related to the selected step Rev 6.1

21 How to use the APQP spreadsheet
The tabs at the bottom of the workbook are hyperlinked to the steps on the APQP sheet Information on APQP and sometimes sample forms are located on these tabs The tabs should also be used to convey information related to the selected step Marked up drawings for 2.2 DFM&A, completed 2.13 MFC, completed Packaging Approval Form are a few examples of items which should be attached to the workbook Larger items such as PFMEAs and Control Plans we ask that upon completion the first page of the document be placed on the corresponding tab and the full copy sent to the SQE for review One of the many advantages of APQP is PPAP related documents, which have to be submitted before the PPAP due date, can be preapproved by Polaris ahead of time by obtaining a GOLD square The Polaris SQE is saying, “This document is ready for PPAP submission”

22 How to use the APQP spreadsheet
PDP Status Tab of Workbook Provides a Snapshot of PDP Progress by the Supplier Populated from APQP Spreadsheet

23 SOP - PPAP One core outcome of APQP is a first pass of the PPAP
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review SOP - PPAP One core outcome of APQP is a first pass of the PPAP Collaboration between Supplier and Polaris should aid in this successful PPAP approval Submit early if possible The primary outcome is successful production launch Success = PV builds with no major quality spills, SOP builds with no quality spills, fulfilled safe launch period, no line down situations, no field actions APQP  Successful SOP

24 How is APQP Tracked? APQP Report Card Queries existing APQP workbooks that are populated by the supplier quality team Tracks APQP completion % vs. plan; along with Critical task completion Automatically color codes data points based on % off plan. Table on left side displays supplier level detail Part-level detail is available through a link to supplier’s APQP workbook APQP Tracking goals and metrics in place; PDP deliverables defined

25 Project Completion - Phase 5 Review
High Level Part Risk Identified pre G2 Heat Map to drive APQP Level (H/M/L) SQE Project Leader assigns key dates APQP Project Kicked off with Supplier Supplier and SQE collaborate to submit and approve key elements Project SOP End APQP with Phase 5 review Project Completion - Phase 5 Review Lessons Learned Variation Reduction Plans KPC Improvement / Monitor Plans

26 Learning Objectives Recap
As a Polaris Supplier, you should understand: Understand the overall process of APQP and when you are required to utilize the APQP process. The importance of a standardized method for APQP Guidelines for APQP How to use the APQP process. Are you comfortable with the APQP process? Polaris CONFIDENTIAL

27 Thank you! Thank you for taking the time to complete the APQP Polaris Training Module. Questions? Please contact your key Supplier Quality or Development Engineer! Thank You! Polaris CONFIDENTIAL


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